CIVIL_STRUCTURAL_ARCHITECTURAL_DESIGN & CONSTRUCTION SPECIFICATIONS

TENDER NO. : E10/09

SCADA CONTROL CENTRE UPGRADE WORK AT UAQ

VOLUME – II

SECTION – 3

GENERAL TECHNICAL SPECIFICATIONS

1 - CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS

E1009 - VOL II - SEC 3.1 - CIVIL_01

VOL II GEN.TECH.SPEC –CIVIL Page 2 of 158

TABLE OF CONTENTS

Page

1.1. DESIGN REQUIREMENTS..............................................................................6

1.2. MATERIALS AND WORKMANSHIP ..............................................................34

1.3. EARTHWORKS...............................................................................................40

1.4. CONCRETE WORKS .....................................................................................60

1.5. BUILDING WORKS.........................................................................................88

1.6. PIPE, DRAINAGE AND CABLE DUCTS......................................................106

1.7. RAISED MODULAR FLOORING .................................................................116

1.8. STEELWORK AND PAINTING.....................................................................123

1.9. ROADS AND SURFACING...........................................................................133

1.10. STRUCTURES FOR OUT DOOR EQUIPMENT .......................................152



1.1. DESIGN REQUIREMENTS



TABLE OF CONTENTS

Page

1.1. DESIGN REQUIREMENTS..........................................................................6

1.1.1. Contractor Design Work...............................................................................6

1.1.2. Design Submissions ....................................................................................7

1.1.3. Design Assumptions ....................................................................................9

1.1.4. Design of Foundations..................................................................................9

1.1.5. Design Loads..............................................................................................12

1.1.5.1. General Assumptions .................................................................................12

1.1.5.2. Seismic Load..............................................................................................12

1.1.5.3. Wind Load...................................................................................................12

1.1.5.4. Load Combinations.....................................................................................13

1.1.5.5. Increase in Soil Bearing Capacity/ Pile Capacity .......................................13

1.1.6. Design of Block work Walls........................................................................13

1.1.6.1. GENERAL...................................................................................................14

1.1.6.2. Material........................................................................................................14

1.1.6.3. Execution ....................................................................................................14

1.1.6.4. Mortar..........................................................................................................15

1.1.6.5. Reinforcement and Fixing Accessories for Brick and Block Work ............15

1.1.6.6. Fixing Accessories .....................................................................................16

1.1.6.7. Damp-Proof Courses .................................................................................16

1.1.6.8. Glass Block Window and Wall Elements...................................................16

1.1.6.9. Workmanship .............................................................................................19

1.1.7. Architectural Design ...................................................................................20

1.1.8. Drainage System Design ...........................................................................22

1.1.9. Sewerage System Design..........................................................................24

1.1.10. Design of Water Supply System................................................................26

1.1.11. Reinforced Concrete Design......................................................................27

1.1.12. Design of Structural Steelwork...................................................................27

1.1.13. Earthing Design ..........................................................................................28

1.1.14. Design Programme....................................................................................28

1.1.15. Thermal Requirements...............................................................................28

1.1.16. Fire Resistance - Building Structure ..........................................................28



1.1.17. Roads and Surfacing..................................................................................29

1.1.18. Temporary Works.......................................................................................30

1.1.19. Submission Time........................................................................................30

1.1.20. APPENDIX 1 ...............................................................................................31



1.1. DESIGN REQUIREMENTS 1.1.1. CONTRACTOR DESIGN WORK Contractor Design Work shall encompass all needed Civil, Structural and Architectural design and engineering works to complete the design of the LDC Building and any associated structures adjoining and connecting it. Such design works shall include but not limited to the analyses, design and applications of any relevant Superstructures and Substructures in the area of work, which also shall include all needed tie-in and external works to any existing building or structure to complete such works. The attached Tender Drawings & Documents are for initial design & applications assessments only & mainly serve as basis for all works relevant to the completion of the project. If the Contractor deemed to foresee a deviated detailed design works for the Civil, Architectural & Structural aspects of the works from the Tender Drawings & Documents, a maximum increase of 20% is allowed for all affected aspects of the works provided such increased shall be proven with relevant technical analysis & calculations and with mutual discussions & coordination to acquire FEWA approval for such increased. The contractor shall be responsible for the technical suitability and adaptability of the Design Work by taking into account all relevant factors and elements affecting such work in its design applications – such as performing actual site survey and measurement of the magnitude and range of the design aspects and applications and consideration of any external utilities and tie-in works including any relocation and divertion of any affected underground utilities lines. Acquisition of any data, documents and drawings relevant to any affected existing structures or underground utilities and cable lines in the vicinity of the work shall be coordinated and acquired by the Contractor with the concerned FEWA authorities or local branches of issuing authorities in the area of works, prior to commencement of the Design Work. The Design Work shall not commence until a reliable Soil Investigation Work is performed and established with official design approval from the Engineer. The reliability of applications of the Soil Investigation Report shall be determined by the Contractor – of which additional soil tests shall be performed in the area of work if in the discretion of the Engineer the results of the previous tests found technically unacceptable and inadequate in its applications on the actual site soil conditions. The Design Work shall be included in the overall Schedule of Works of which, the Engineer shall be notified in case such Design Programmed is deemed deviated from the approved Schedule of Works owing to design changes brought upon by the effects of unforeseen actual situations in the area of works – such as unreliable data on existing underground utilities. The Design Work shall be performed in accordance with the following Building Codes of Practice:

- British Standard Institution (BSI)

- European Code of Practice (EUROCODE)

- Dutsches Standards (DIN)

- Uniform Building Code 1997 (UBC)

- American Concrete Institute (ACI)



- American Institute of Steel Construction (AISC)

- American Association of State Highway and Transportation Officials (AASTHO)

- American Welding Society (AWS)

- American Water Works Association (AWWA) The Design Work shall be executed considering all possible applied loading conditions including any foreseeable post and pre-occupancy design loading applications for such works. Prior to commencement of Detail Design (DD) an initial Preliminary Design (PD) of the Design Work shall be performed and subsequently submitted for Engineer’s scrutiny and approval. The Preliminary Design (PD) shall be based from the attached Tender Drawings and Documents, which shall indicate the initial range of sizes of the structural members. The structural frame system of the LDC building including its foundation and any external substructures and civil tie-in works shall be of reinforced concrete moment resisting frames. Other minor elements of the Design Work shall be of structural steel framing system such as Car Park Shades, Roofing Elements and other Equipment Supports structures. Design activities – such as analyses, theoretical assumptions, assessments, calculations, graphical interfaces and design sketches, shall be so detailed and comprehensively presented for complete clarity of its intended applications proportionate with the aspects of the Design Work. Relevant Design Calculation Report shall be performed on each crucial aspect of the Design Work with the use of sophisticated structural analysis and design computer software – such as STAADPRO. Manual design calculations shall be technically comprehensive in its entirety of applications. 1.1.2. DESIGN SUBMISSIONS The design analysis shall be a written explanation of the project design process, included as a part of each design submission. Written material may be illustrated by calculations, diagrams, and sketches to convey design concepts. The design analysis shall be presented on size A4 paper except that multiples of this sheet size may be used when required for graphs or other special illustration forms. All sheets shall be of reproducible quality. The material may be typewritten, handwritten or a combination thereof, provided it is legible. The design shall conform to minimum code requirements as applicable. Analysis shall be based on the latest edition of the specified codes at the time the contract is awarded. It shall include occupancy classification, construction type, allowable building area, exits and other applicable code requirements. The basis of design shall include a comprehensive statement on concept development and specific criteria to be used in the design of the project. A brief description and outline of civil, architectural, structural, drainage and water supply systems shall be included. Design calculations are a part of the design analysis. When calculations are voluminous, they shall be bound separately from the narrative part of the design analysis, and shall incorporate a title page and index for each volume. The source of loading conditions, supplementary sketches, graphs, formulas, and references shall be identified. Assumptions and conclusions shall be explained. Calculation sheets shall carry the project title, contract number, the initials of the persons preparing and checking the calculations, and the dates the work was performed. No portion of the calculations shall



be computed and checked by the same person. Calculations may be prepared in any convenient system of units, but all results shall be converted to and shown in Standard International (SI) units. When an Automatic Data Processing Systems (ADPS) such as STAADPRO, is used to perform calculations, the design analysis shall include descriptions of the computer programs used and copies of the ADPS input data and output summaries. The description shall also include: a) The design method, including assumptions, theories, and formulas used. b) Any applicable diagrams adequately identified. c) All necessary explanations of the computer printout format, symbols and

abbreviations. d) Adequate and consistent notations. Each set of computer printouts shall be preceded by an index. If several sets of computations are submitted, they shall be accompanied by a general table of contents in addition to the individual indexes. Drawing scales shall be of metric scales and the metric system shall be used on all drawings. The following metric scales are recommended for general usage on drawings; however, they are not meant to be mandatory. Should another scale be more appropriate in a particular instance, it may be used: a) Site plans and layouts scale: 1: 200, 1: 300, 1: 500 b) Plans and elevations scale: 1: 50 (preferred), 1: 100 c) Sections and details scale: 1: 5, 1: 10, 1: 20, 1: 50 Notes shall be presented in clear and concise statements. A note is not adequate if it does not convey the exact design intent. All notes shall be listed on the right hand side of the drawing. Drawing background indications shall be thin or screened, single-line outline indications showing equipment, structures, or supports which must be shown to indicate locations and clearances. Lettering shall be vertical or slanted right, but both shall not be used in the same drawing package. The lettering in titles shall be a minimum of 6mm high; all other lettering shall be a minimum of 3mm high. Plans, sections, and details shall be laid out on the sheet in such a manner that the portion on the right side of the sheet above the title block is reserve for indicating notes, key plan, schedules, revisions and other miscellaneous requirements. The north arrow shall preferably be placed in the upper left corner of each plan drawing. Drawing size shall preferably be on A1 size sheet, but size A2 and A3 can also be used for other drawings. Drawing symbols shall be as per internationally recognized or commonly used drawing symbols.



Required quantity of submitted drawings depends on the outcome of the design process of each aspects of structure being considered but shall be proportionate to their intended applications. All needed drawings and documents for civil, structural and architectural aspects of the Scope of Works shall be submitted to the Engineer/FEWA for approval prior to commencement of each aspect of the works. Such drawings and documents include but not limited to: Preliminary design drawings and documents – i.e. design calculation report, Detail design drawings and documents, Construction Methodologies documents for each aspects of construction activities, Material submittals documents, and Fabrication and Installation drawings for the works. 1.1.3. DESIGN ASSUMPTIONS All design assumptions shall be based on the Building Codes of Practice recommended assumptive behavior of each aspect or elements of structures being considered, and established engineering formulas relevant to the type of structure being design. Wind Loads shall be in accordance with the British Standard Code of Practice for wind loading applications except that, wind speed shall be as per UAE maximum windstorm data in the vicinity of the structure being considered. Seismic Loads shall be in accordance with the Uniform Building Code 1997, with applied loading corresponding to zone area of 2A, and seismic zone factor of 0.15. Thermal Loads shall have a range of +15º/-10º for internal structures, and +32º/-10º range for external structures. Mechanical and electrical equipment loads shall be as per relevant manufacturer’s recommended equipment weight including any impact loads. Creep and shrinkage loads shall be as per the British Standard Building Code requirements. Lateral and vertical displacement of structural members shall be in accordance with the Building Codes displacement limits with inclusion of mechanical and electrical equipment elements displacement constrains. Wind and Seismic loads shall not be assumed specifically occurring at the same frame of time. Structures shall be designed so as not to exceed the stress limits – i.e. tensile, compression, torsion stresses, in any points of restrains of the member, as stipulated on the Building Codes of Practice. Load combinations shall be as stated on the above-mentioned Building Codes of Practice. 1.1.4. DESIGN OF FOUNDATIONS Foundations shall be designed in accordance with the requirements of the above-mentioned Building Codes of Practice.



Throughout the Works the Contractor shall be required to base all foundations on a sound/compacted formation. All formations must receive the FEWA Engineer's approval for use before being blinded with concrete. All trench and pit covers, etc., shall be designed for the same minimum loadings. In plot lay down and maintenance areas, all trench and pit covers shall be designed to withstand all possible applied loadings including heavy truck loads. Where ground improvement methods are adopted these shall be to the approval of the FEWA Engineer. All foundations must be entirely located inside the boundary of the allocated site plot. Where piling is adopted the design of the piles and the foundations shall be to the approval of the FEWA Engineer. Where foundations are supported on piles they shall be adequately and properly tied to the pile heads. Allowance is to be made for the provision of preliminary test piles to be placed and tested before any construction and during the design, in order to obtain suitable working loads for the proposed piles. Foundation for steelwork and other forms of structure shall be designed to resist all loads and movements from the framework and wind/seismic forces. They shall be suitable for building-in holding down bolts, which should be provided with coring tubes, anchor plates or steelwork. The foundations shall be placed at the appropriate levels to clear adjacent pipes. All foundations are to be suitably protected from chemically aggressive ground conditions by tanking with a bitumen type self adhesive membrane. Shallow Foundations are classified as Mat, Pad, Strip and Isolated foundations relevant to their intended applications on the support points of each structure. Shallow foundations shall be designed to resist all possible assumptive induced reactionary loadings of the structure including the effects of surrounding and underlying soil stratums. Expected differential and maximum settlement shall be checked in conformity with the requirements as stipulated on Soil Investigation Report recommended maximum foundations settlements as well as per established empirical formulas in ascertaining the capacity of such foundations against such expected maximum settlements. Stability checked of shallow foundations shall be performed with a factor of safety of at least 1.50 for lateral and overturning stability. Effects of soil friction up to a soil depth of 2.0 meter from the ground or finish grade level shall be disregarded in determining the resistance of the foundation against applied uplift forces. Soil on top of the foundations shall be assumed to resist against induced lateral and overturning loads. Effects of triangular soil edges of soil frustum cone shall be assumed not to contribute on stability requirements – only the vertically aligned soil on top of the foundations shall be considered. Foundations shall be checked with the code requirement on crack width consideration. Foundations adjacent to roads shall be designed to resist surcharge loads brought upon by the applied vehicular loading on such roads in accordance with the Building Code requirements. Tension development length of plinth longitudinal bars embedded on shallow foundations shall be checked in accordance with the ACI code. All shallow foundations shall be waterproofed with membrane waterproofing system.



Deep Foundations for the LDC Building are classified as piles of at least 6.0 meter length tied together with a pile cap that serve as the columns base of supports. Deep Foundations shall be applied as per Soil Investigation Report recommended foundation applications on the LDC Building. The initial 2.0 meter depth of piles soil frustum shall be not assumed to resist friction resistance against applied uplift or compression forces. Effects of ground water level shall be considered in ascertaining the overall resistance of the set of piles on each pile cap in accordance with the Soil Report findings. The following design parameters shall also be considered in the design of Deep Foundations: a) Maximum Ultimate Uplift and Shear forces shall be selected for the design of

piles. b) It shall be assumed that soil doesn’t offer any skin resistance up to a depth of 2m

from the Natural Ground Level. c) For design purposes, it shall be assumed that Ground water Table is 2m above

the measured level. Accordingly, the unit weights of soil and concrete shall be adjusted in the calculations.

d) Angle of Friction shall be assumed as follows:

SPT Values Friction Angle

Less than or equal to 10 0

More than 10 but less than 25 30

More than or equal to 25 but less than 35 32

More than or equal to 35 34

a) Value of Ks= 0.62.

b) Minimum length of pile shall be considered as 6.0 meter below Natural Ground Level.

c) For Pile Weight calculation, actual length of pile shall be calculated including pile cap and the weight of inverted soil cone-Frustum.

d) Skin friction in rock shall be assumed to be 10% of the minimum UCS value in the rock layers as mentioned in soil investigation report.

e) For piles compression resistance, bearing of piles on rock strata can be assumed to combined with the piles skin friction.

f) Pile length shall be rechecked based on inverted cone-Frustum Angle Method.

g) While deciding the pile length, the ratio of ultimate uplift capacity against ultimate uplift forces shall not be less than 1.2.

h) Design of Reinforcement for the piles shall take into account additional moments due to out of plumb, out of position and shear force. The Contractor shall provide the charts for interaction diagram for calculation of reinforcement.

i) The nominal cover to reinforcement shall be 75mm. The center to center spacing of the main reinforcement of piles shall not be less than 100mm.

j) Piles cut-off lengths levels shall be established based from the piles starter bars as well as the plinths longitudinal bars development length unto the pile caps. Design thickness of the pile caps shall also be determined proportionate to the required development lengths of such bars in accordance with the ACI code.



k) All pile caps shall be waterproofed with membrane waterproofing system. 1.1.5. DESIGN LOADS Generally loadings shall be based on British Standard Code of Practice or Uniform Building Code 1997, however the following minimum design loadings shall be considered. 1.1.5.1. General Assumptions The minimum requirements for loads to be applied for the static analysis of both sub and superstructure works shall be as follows, in addition to the equipment and installation loads that shall also be considered: - Live load for building roofs

(A/C equipment and foundations to be considered additionally) 1.5 kN/m

2

- Battery rooms, stores 10.0 kN/m2

- Control Rooms 5.0 kN/m2

- Switchgear Rooms 10.0 kN/m2

- Offices 5.0 kN/m2

- Kitchens, corridors, staircases, etc. 5.0 kN/m2

- Plant Rooms 10.0 kN/m2

- Additional dead load for suspended ceiling, pipes, AC system, etc

1.0 kN/m2

- Roads and pavements, gutters SLW 60, DIN 1072 - Water tanks, septic tanks, etc. in road areas SLW 60, DIN 1072

Vehicular loadings to be considered for design works shall be the greater value of ascertained uniform & concentrated loadings applications on each aspects of works as specified on the DIN 1072 Code for Vehicular Loads. 1.1.5.2. Seismic Load Static analysis shall be carried out for seismic loads calculated as static shear forces based on seismic coefficient of 0.15 in accordance with Zone 2A of the Uniform Building Code 1997. The Seismic Importance Factor shall be considered as 1.0. All other parameters must be determined in accordance with UBC and highlighted in design criteria. Structural analysis and design shall be started after approval of such parameters. Seismic P-delta effects shall be considered in the design of the LDC Building in accordance with the UBC 1997 Section 1630.1.3. The structural requirements on general robustness and disproportionate collapse shall be applied on the design of LDC Building structural frame systems in accordance with the requirements of the UBC 1997 and BS 8110 Building Codes. The buildings and structures shall meet the serviceability requirements of the British Standard (BS) and Uniform Building Code (UBC1997). 1.1.5.3. Wind Load



Wind Loads shall be as per the requirements as stipulated on the British Standard Code for Wind Loadings. However, site wind speed shall be as specified on the UAE windstorm database.

1.1.5.4. Load Combinations Load combinations shall be in accordance with the load combinations as specified on the UBC 1997, ACI, and BS 8110 Codes, whichever are higher. 1.1.5.5. Increase in Soil Bearing Capacity/ Pile Capacity For load combinations with wind and seismic loads, soil bearing capacity can be increased by 25% over the values mentioned in the Soil investigation report. For load combinations with wind and seismic loads, pile capacity can be increased by 25% as per pile design. Reinforced concrete members below ground level shall be designed with a crack width not more than 0.2 mm in accordance with the British Standard Building Code. Accordingly, structural members above ground level shall be designed with a crack width not exceeding 0.25mm. Lifts and other equipment loads shall have impact loads corresponding to the percentages of their static design loadings in all directions. 1.1.6. DESIGN OF BLOCK WORK WALLS Design of Block Work shall be as per the specification stated in this document and in accordance with the relevant British Standard Code of Practice for Masonry Work. Structures of masonry construction shall be designed such that the masonry is not in contact with the soil. Block walls at the LDC building shall have their bases supported on grade beams or on thickened slabs that serve as wall footings. All walls and wall panels shall be of sufficient strength and thickness and adequately secured to the structural frame to withstand superimposed loads, self-weight, wind and seismic pressures without cracking or distortion. Block work generally shall be isolated from the structural members but dowelled to prevent collapse in the event of earthquake. All block work walls shall be reinforced every second course with expanded metal lathing or equal laid in the horizontal bed joint with a minimum of 100 mm laps at ends and junctions. All wall panels shall be so designed and constructed with expansion joints generally at maximum 4 m centers as to prevent cracking or distortion through thermal movements. The expansion joints are to be formed with approved flexible metal closer strips. Stiffener

beams and columns are to be provided wherever block work exceeds 15 m2

. Block wall shall not exceed 5M in width and 3M in height.



1.1.6.1. GENERAL This part of the Specification shall cover all items related to all kind of masonry and plaster work in accordance with the structural analysis and as shown on the approved drawings required for the tendered Project, as well as all auxiliary works. All works shall further be carried out in full compliance with all local rules and regulations and the Specification shall further be read, if applicable for the Project. 1.1.6.2. Material The material to be used for masonry work comprises the following:

· Natural stones, clay bricks, calcium silicate bricks, solid or hollow concrete blocks, blocks, stones and wall boards made of cellular concrete blocks, ornamental stones (e.g. claustra stones) out of concrete, and any other type of blocks and stone artificially produced

· Light weight concrete blocks and wall boards, gypsum plaster boards

· Hollow glass blocks

· Insulating and filling material

· Binding agents

· Metal accessories. The material above shall be generally standardised as specified hereafter. 1.1.6.3. Execution Strength and execution of the masonry work shall conform either to DIN or BS Codes of Practice. Masonry work, arranging and bedding bricks, blocks and boards, etc., shall be executed in mortar to form a homogeneous mass and to bond them in such a manner that point or other loads and stresses are dispersed and distributed through the mass without the structure tending to disintegrate. Block work partitions less than 200 mm in thickness shall be solid block. Reinforced concrete frames of at least 200 mm width and the same thickness of the wall shall strengthen all opining through the block walls. Block work more than 3 m in height shall be reinforced with reinforced concrete stiffening frame work comprising of 200 x 300 mm verticals at 4.00 meter centres and 200 x 300 mm horizontals at mid-height or at every 3.00 meters in case wall height is bigger than 6.00 meters. Brick work more than 3m in height shall be properly supported by steel angels fixed to the concrete stiffeners/beams Solid block works shall be provided wherever service pipes, cables, etc. are passing in wall (e.g. auxiliary electrical rooms, bathrooms, kitchens, etc.)



Precaution shall be taken to prevent the work drying too quickly, especially in hot weather. All bricks, blocks and boards shall be saturated before bedding to prevent them absorbing the moisture from the mortar, and also to remove all loose dust from the surface in contact with the mortar. Brickwork and or block/board work, which has not been thoroughly wetted and has developed a thin crack between the brick/block/board and the mortar joint, shall be pulled down and rebuilt. All masonry work shall be suspended during extreme weather unless adequately protected. Block work under the ground slab, retaining walls and around foundations shall be solid block at least 200 mm thick and made by SRC or MSRC (type-II) cement according to under ground soil conditions. Tests and Properties All concrete blocks shall comply with BS 6073. The compressive strength of the blocks/bricks shall comply with the following: Concrete hollow blocks: Average of 10 blocks 7.0 N/sq. mm Lowest individual block 5.5 N/sq. mm Concrete solid blocks: Average of 10 blocks 13 N/sq. mm Lowest individual block 8.0 N/sq. mm Sand lime bricks: Average of 10 bricks 10 N/sq. mm Lowest individual bricks 7.5 N/sq. mm Tests shall be conducted for every 200 m2 of walls/each consignment of block/brick brought to site. 1.1.6.4. Mortar Mortar for block work shall be cement mortar in the proportions 1 : 3 to 1 : 4 (Cement to sand). All mortar shall be mixed in a power-driven mixer and, in addition, all materials shall be screened before mixing to remove lumps. Mortar, whether with or without plasticiser, shall be mixed only in sufficient quantity for the work immediately in hand and no partly set mortar shall be used. Compressive strength of mortar after 7 days shall not be less than 10 N/mm2. 1.1.6.5. Reinforcement and Fixing Accessories for Brick and Block Work Brick or block work shall be provided with horizontal reinforcement. Reinforcement shall be high tensile galvanised steel mesh, 6 cm wide for 10 cm walls and 12 cm wide for 20 cm walls. The reinforcement shall be laid in as long lengths as practicable without laps. Where joints are necessary, the lengths shall be lapped not less than 30 cm, except at corners or junctions, where the lap shall be equal to the width of the reinforcement and the reinforcement in one wall bent over that in the other. Application: every second layer of block and at 400 mm for brick. Fixed in walls/ columns every 450 mm.



1.1.6.6. Fixing Accessories

· Channel slots for block/bricks restraint

- Galvanised MS channel.

· Sliding ties for block restraint

- Galvanised MS size 30 x 125mm dove tail type to fit the channel.

· Lateral restraint ties for movement joints

- A butting columns or return walls, galvanized MS and plastic sleeves, fixing at 600 mm centres “Halfen/HCT 3/9 SP or equivalent”

· For block/bricks components

- Galvanised MS, butterfly ties of 250 mm length.

1.1.6.7. Damp-Proof Courses Damp-proof courses shall be laid on and bedded in a bed of 1 : 4 cement mortar in as long lengths as practicable. Where joints have to be made, they must be lapped at least 20 cm in the runs and for full width on corners and the meeting surfaces, sealed with an adequate application of black bituminous water-proofing paste. At ground floor levels, the damp-proof course for a wall shall extend to the full width on top of first row of blocks. Exposed DPC shall be protected from direct sun. The vertical damp-proof course at reveals shall extend the full width of the return. 1.1.6.8. Glass Block Window and Wall Elements General Glass block windows and wall elements shall be executed as per DIN and Manufacturer’s instructions. Bidder/Contractor shall submit manufacturer’s data sheets, catalogues and installation recommendations. Following minimum requirements shall prevail: · Number of layers : One layers of glass block walls

with cavity in between · Mortar : Masonry cement : Sand : 1 : 4 · Painting : White cement and Marble powder · External/Waterproof finishing : Paint and silicone sealant around all openings · Color : Normally clear glass · Fire rating for glass block walls for single skin glass walls : = 90 minutes. Accessories

· Reinforcement – 8 mm diameter stainless steel rods, formed into a ladder with short rods welded at approx. 400 mm

· Stainless steel double rod joint panel reinforcement to be placed at every horizontal and every second vertical course and welded to a galvanized MS plate anchor frame fixed to the structure

· Place the anchor frame over a full jamb around the opining. Place the sliding strips and flexible boards.

· Apply a silicone sealing compound at all internal surround frame junctions. And apply external quality sealant at all external surround frame junction.



Application For natural lighting on all external walls of fire rated equipment rooms, staircases, and store rooms. Total glass block area shall be approximately equal to 10% of the room area. External Cavity Walls All external brick or block cavity walls are to be built with a cavity of 5 cm nominal width. The two leaves of the wall shall be connected every second course vertically and not more than 0.80 cm apart horizontally with wall ties. Tie shall be laid with a light fall towards the external leaf and shall be kept clear of accumulations of mortar droppings during the progress of the work. Cavity walls may also be filled with insulating material of extruded polystyrene boards with minimum density of 30kg/m3 or similar in the free space if so shown on the Drawings or instructed by the Engineer. At the top end and to the ground the cavity walls shall be bonded together with a full course of masonry bricks or blocks. Lintels Openings in masonry walls shall either be bridged by vertical brick arches (with soldier courses) or by reinforced concrete lintels. The type of bridging shall be indicated on the Drawings. Joints Without affecting the aesthetics and structural stability of any building (or part of building), permanent joints shall be provided in brickwork and blockwork to allow for expansion and contraction caused by temperature changes, shrinkage and moisture movement. Unless there are specific requirements (e.g. stability of superstructure framework), compressible joints fillers shall be used to form the joints, together with protective sealers. Pointing If masonry is to be pointed, the masonry mortar shall be raked out about 1 cm deep while it is still fresh. Immediately before pointing, the faces shall be thoroughly wetted and cleaned with brush and water. Except for natural stones, up to 2% hydrochloric acid may be added to the cleaning water. The faces washed with water/acid mixture shall be rinsed thoroughly. The masonry shall then be pointed with the specified mortar in the manner and color stipulated. The cement mortar for the pointing shall be in the ratio of 1:3 to 1:2. Permissible Tolerances The dimensional tolerances of masonry works in building construction or for other structures in respect of alignments, clearance of openings, length, height, thickness, unevenness, shall comply with the categories of accuracy listed in the table hereafter with categories defined as follows:



CATEGORY NO.

5 Precast stonework, such as cast stone sills, lintels, jambs, stone stairs and steps, walls ashlared with natural or cast stones, etc., manufactured of fine aggregates.

6 Precast stone works as summarized above under category No. 5, but out of medium size aggregates.

7 Precast stone works as summarized under No. 5, but out of coarse aggregates

8 Facing brickwork, stone slabs, facing, ceramic walls, etc.

9 Brickwork and walls to be covered with plaster, lining or other finishings, not exposed to permanent view.

10 Brickwork construction, where less dimensional accuracy is required such as underground foundations, retaining walls, etc.

LIMITS OF DEVIATIONS IN MASONRY WORKS IN mm WITHIN DIMENSIONS WITHIN THE RANGE OF:

Category of Accuracy

Up to 100 100 to 250 250 to

1.000

1.000 to 2.500

2.500 to 10.000

Above 10.000

No.: 5 0.8 1.2 2.0 2.5 3.0 4.0

No.: 6 1.3 2.0 3.0 4.0 5.0 6.0

No.: 7 2.0 3.0 5.0 6.0 8.0 14.0

No.: 8 3.0 5.0 8.0 10.0 12.5 16.0

No.: 9 5.0 8.0 12.5 16.0 20.0 25.0

No.:10 8.0 12.5 20.0 25.0 30.0 40.0

Plaster Works Materials



Sand Sand for cement plastering shall be clean, sieved, and - if necessary - washed in potable water and conform to Specifications for building sands from natural sources BS 1198, 1199 and 1200:1976, with:

· Amendment No.1 – May 1984

· Amendment No.2 – April 1985

· Amendment No.3 – April 1986 Or the relevant DIN Standard. Sand contamination limits shall not exceed 0.06 % for chlorides content and 0.04 % for sulphate content. Additives Additives may only be used after FEWA approval, shall only be obtained from an approved source. Use is to be done in adherence with the manufacturer's technical data sheet. Metal Accessories All exposed/partially exposed metal accessories shall be of stainless steel. All embedded metal accessories shall be steel galvanised proposed metal accessories shall comply with the following:

· G.I. Expanded metal lathing BS 1369

· G.I. Nails and washers for fixing metal lathing hall be flat head galvanised nails BS 1202

· Wire shall be 1.2 mm diameter BS 443

· SS plaster stop boards and angle boards. BS 1448 1.1.6.9. Workmanship General All workmanship for cement plastering works shall follow the recommendation laid down in the relevant standards (DIN or BS 5492). Surfaces of undercoats shall be well prepared and cleaned to provide a good key for subsequent and / or finishing coats. Screed marks or making good on undercoats shall not show through the finishing coats. All surfaces to be plastered shall first be dashed with a mixture of Portland Cement and Sand (450 kg cement: 1 m3 sand) to form a key. Dashed surface shall be cured for at least 3 days before starting plaster works. Plastering shall normally be applied in one coat. Surfaces shall be wetted before the application of the first coat, which shall be finished flat and vertical by straight edge, and scored to form a key. Thickness of the plaster coat shall be 10-15 mm. Immediately



before application of the second coat, the surface of the first coat shall be thoroughly wetted again. Mortar joints in block and brickwork have to be racked out to a depth of at least 15mm. Concrete surfaces have to be roughened prior to plastering and – like any other surface as directed by FEWA shall be treated with an approved bonding agent to provide an adequate key and bond. Joints between differing materials (other than the main reinforced concrete members and the block walls) shall be reinforced. This shall apply where walls join stiffeners, concrete frames, etc., meet and where cracks are likely to develop, and/or wherever directed by FEWA. Reinforcement shall consist of a strip of approved galvanised wire mesh (10 to 15 mm hexagonal mesh), min. 150 mm wide, or of an approved expanded metal with galvanised nails and washers or galvanised staples or similar. Any reinforcing mesh shall be fixed at both edges at intervals not exceeding 50mm, or as required, and the reinforcement shall be completely embedded in the undercoat of plaster. If any joint is between the main concrete elements (columns, beams etc.) and block/brick work, a definite break should be made through back and remaining gap shall be filled with approved sealant to cover unavoidable cracks between these materials. Surfaces described as trowelled smooth shall be finished with a steel or celluloid trowel to a smooth flat surface free from trowel marks. Surfaces described as floated shall be finished with a wood or felt float to a flat surface free from trowel marks. 1.1.7. ARCHITECTURAL DESIGN All Architectural Design shall be mainly in accordance with the Engineer/FEWA requirements and in conformity with relevant international Architectural Design Code of Practice. The attached tender drawings are for preliminary assessments of needed design works only and as such are not fixed or limited in their intended architectural applications & requirements for the stated works. It is the Tenderer/Contractor discretion for the needed detailed design applications & requirements for the works – and hence a maximum increase of 20% is allowed, however, such 20% increase is subject to FEWA assessments & approval of its application. The building’s form, orientation and external fabrication shall be design primarily to:

1. Diffuse/baffle direct sunlight and reduce glare.

2. Reduce solar gain and maintain comfort levels by air conditioning.

3. Exclude wind-borne dust and insects.

4. Resist flash flooding and exclude rainfall of an intensity and duration expected of a 50 year storm.

5. Incorporate selected materials, elements and components to minimize maintenance.

6. Arrange and relate areas to provide formation of sheltered spaces within and immediately external to the building.



Openable window units shall be provided to permit natural ventilation as a preference or, in event of mechanical break down. Windows and Screenings: Daylight factor: Calculation shall be made of window sizing and sitting with recessions and/or applied screenings to reduce direct light intake. Oversizing of glass area shall be avoided and east/west outlook minimized to the essential. The installation of double glazed units shall be applied to large area glazing where potential heat gain is considered a significant design factor in calculation of air conditioning loadings. Selected materials and equipment with proven performance and low-to-negligible. Provisions for the physically handicapped shall be included in the LDC Building and in the parking area. Provisions shall consist of barrier free access and other requirements in compliance with ANSI A117.1 Code and International Architectural Code of Practice. Graphics, signs, and identifying devices shall be in both Arabic and English wording. Exterior material selection may include , but not limited to, masonry or concrete, cast-in-place or precast concrete, insulated metal side-wall cladding systems, glass fibre reinforced concrete and plastics. Finishes may include: Exposed aggregates, bush hammered, etched or sands blasted concrete, cement plaster render, ceramics, timber and exterior paint systems. Reduced textures should be selected to offset potential staining and dust adhesion. An initial schedule of finishes for external & internal elements & surfaces of the LDC Building is provided with this tender documents which shall be the base for the Contractor’s range & scope of finishing works. However, such schedule of finishes is not limited; the Contractor shall recommend & specifically indicate in its tender if in its discretion such finishes needed to be modified to suit acceptable aesthetical & applicable conditions within & outside the LDC Building but with FEWA approval for the same. All office & control rooms including other rooms that are ascertained to have office working tables with or without specific computer units shall be provided with power & communication floor boxes installed on their floors. The floor boxes shall have sufficient outlets for power & communication cables – such as internet/telephone lines. Quantity of the floor boxes shall be specifically included in the Tender Price & its final applications shall be as per FEWA approval. All doors & windows in the LDC Building shall be equipped with sensor for ISBMS System interfaces. The sensor shall be provided & installed on each door & window complete with all the needed elements of such sensor including any required wiring connection to the ISBMS System. Exterior floors, walls, and roof systems shall achieve thermal transmittance factors not exceeding:

- Floor and Wall : 0.57 W/m² - K (0.1Btu/Hr - Ft² - °F)

- Roof : 0.28 W/m² - K (0.05Btu/Hr - Ft² - °F) In walls vapor barrier shall be on the warm side of the insulation.



All exterior metal work shall be non-corrosive or have an approved anti-corrosive treatment. Suitability, durability, maintainability and replaceability shall be prime factors in the material selection process. Toilets and Bathing Facilities:

1. Water Closet Orientation: All water closets shall be floor mounted and the axis of features shall be faced away from Makkah. The positioning shall be at least 15 degrees either side of the Makkah axis. In prayer area, positioning of features shall be 90 degrees from that axis.

2. A hand-held perineal spray hose with wall mounted hanging hook and, tip flow control shall be installed at all water closets to the right of the user.

All water closets shall be western style and shall be floor mounted tank type complete with elongated siphon jet action bowl. Trim shall be chromium-plated brass. Tank shall be adjustable for maximum 14 liter flow and shall be mounted on the upper back of the water closet. Clean-up sink shall be provided in all toilet rooms. Floor drains shall be provided in toilet rooms, kitchens, mechanical equipment rooms and other areas with a source of water where regular wash-down is required. Such floor areas shall be sloped to trap-sealed floor drains. Hand dryer shall be provided & installed in all toilets. Specification of the Hand dryer shall be at least 1Ph-415V, 2000 watts, 50Hz or as per equipment schedule subject to FEWA requirement & approval however it shall be specifically made in Germany. Contractor shall submit lux calculations for all areas in the LDC Building including the external lighting system. In addition to the aesthetical applications of the illumination design, effects of office working requirements including foreseeable arrangement of interior furniture elements on each room shall be considered in the calculations. All rooms in the LDC Building except stairs areas shall be provided with suspended ceiling. Material elements of the suspended ceiling shall be as specified in this specification – 1.5.1.22. A projector shall be provided in the Meeting Room. Quality, size & capacity of the projector shall be as per architectural design application with due consideration to its intended purpose. The projector shall be of sophisticated quality and be of European made. Contractor to submit material approval with product catalogs for the Projector for FEWA approval. The Security/Watchman Room shall be provided at the main entrance gate of the plot. Such room shall be equipped with toilet, complete with wash basin & water closet; accordingly a small kitchen with sink shall be provided on such room with drainage discharge to the drainage system in the area of works. Similarly, the same shall be provided with the required water supply. 1.1.8. DRAINAGE SYSTEM DESIGN Storm Drainage Design:



Design Frequency: a) Closed Conduits

1. 50 Year Storm – for design of a storm drain that will be located or connected in a natural water course or wadi.

2. 25 Year Storm – for design of a storm drain with connection adjacent to residential area.

3. 10 Year Storm – for all other storm drain design. b) Open Channels

1. 50 Year Storm – for design of channels located or connected on a natural water course or wadi.

2. 10 Year Storm – for design of a road side channels.

3. 10 Year Storm – for all other open channel design with sufficient free board to contain a storm of 50 year frequency.

The Rational Formula shall be used in determination of Storm Surface Runoff: Rational Formula: Q = 0.28 (CIA) Where: Q = Runoff in m³/sec. I = Critical rainfall intensity in mm/hr. A = Drainage catchment area in square kilometer. C = Weighted runoff coefficient. Runoff Coefficients: Description of Area Runoff Coefficient LDC Building Roof 0.75 to 0.95 Concrete Pavement 0.70 to 0.95 Brick Paths 0.70 to 0.85 Other areas on site 0.50 to 0.80 Design of the Drainage System: The drainage system shall be designed for uniform flow. The velocity shall be calculated based from the Manning’s formula as follows: V = (1/n) (R2/3) (S1/2) Q = AV Where: Q = Discharge in m³/sec. V = Velocity in m/sec. A = Cross sectional area of flow in m² R = Hydraulic radius A/P in m. P = Wetted perimeter in m. S = Slope of the energy gradient m/m. N = Roughness coefficient



Type of Material “n” value: Concrete and asphalt pavement : 0.015 Sand and gravel area : 0.025 Gravel area : 0.030 Natural Wadi Areas : 0.040 – 0.045 General Storm Drain Design Criteria: Surface Drainage: Surface drainage shall require maximum use of sheet flow with collection or diversion ditches. Runoff from adjacent areas shall be diverted, as required to minimize storm damage to the project site. Culverts: Culverts shall be provided as required for drainage under roads. Culverts shall be designed with a minimum inside diameter of 500mm. Such culverts shall withstand the designed vehicular loadings. Storm Drain Lines: Storm drain lines shall be designed with a minimum inside diameter of 500mm for main lines and 300mm for branch lines less than 10 meters long. Storm Drain Manholes: Storm drain manholes shall be designed for straight through flow. Manholes shall have removable cast iron covers capable of supporting a total load of 7272 kg. Grate type covers shall be used when manholes are used as required. Manholes shall be provided at changes in direction and at changes in pipe size. Manholes shall be spaced as follows:

Conduit 750mm in diameter or less 90 m.o.c.

750mm to 1200mm in diameter 120 m.o.c.

Reinforced concrete box conduit 150 m.o.c. Subdrains shall be designed with perforated pipe in collection areas and closed pipes on effluent lines. All pipe joints shall be closed. The minimum cover over the storm drain line shall be 1.00 meter, and shall be designed to support the superimposed vehicular loading over the drain line. 1.1.9. SEWERAGE SYSTEM DESIGN 1. Quantity of Flow: The average per capita sewage flow on the LDC Building including the site area is assumed to have 140 liters per day. However, the designed Peak Flow factor shall be determined based from the expected maximum number of persons in the LDC Building design, and if the latter produced higher value of per capita sewage flow, the value shall be used in the design. The sewerage system shall be designed using hydraulic analysis of the following Manning’s formula:



V = (1/n) (R2/3) (S1/2) V = (лDІ/4)(1/n) (R2/3) (S1/2) Q = AV Where: Q = Discharge in m³/sec. V = Velocity in m/sec. A = Cross sectional area of flow in m² R = Hydraulic radius A/P in m. P = Wetted perimeter in m. S = Slope of the energy gradient m/m. N = Roughness coefficient Type of Material “n” value to be used for sewerage system design: Vitrified Clay Pipe : 0.013 Plastic Pipe (uPVC) : 0.012 Glass Reinforced Pipe (GRP) : 0.012 Minimum Pipe Slopes for Sewer Mains (uPVC Pipe), however higher values shall be applied based from design calculations for the actual sewerage system applications on the area of work: Pipe Size in mm: Slope m/m 160 0.0100 180 0.0050 200 0.0042 225 0.0036 250 0.0032 280 0.0027 315 0.0023 355 0.0020 400 0.0017 450 0.0015 500 0.0013 560 0.0011 General Sewer Line Design Criteria: LDC building laterals shall have a minimum pipe diameter of 160mm to be laid to a minimum slope of 1%. Sewer mains shall have a minimum pipe diameter of 200mm. All sewer lines 250mm or smaller in diameter shall be designed not more than half full at peak flow. Sewer lines larger than 250mm in diameter shall be designed not more than ¾ full at peak flow. All sewer lines shall be designed to provide a minimum velocity of 0.70 m/sec at peak flow condition. Manholes shall be installed at the beginning and ends of a sewer lines and at all changes in pipe directions, slope or change in pipe sizes. Along straight runs, manholes shall be spaced not greater than 100 meters for pipe sizes 200mm to 400mm and 150 meters for larger pipes. The minimum inside diameter of manhole shall be 1.20 meters. Whenever a



sewer enters a manhole, at an elevation 450mm or more above the manhole floor, a drop type manhole shall be used. Cleanouts (C.O.) may be used in lieu of manholes at the head end of a sewer line and along sewer laterals which are collectors for building sewers. The maximum spacing from C.O. to C.O. shall not exceed 30.00 meters and the spacing from C.O. to manhole shall not exceed 70 meters. Minimum cover over sewer line shall not be less than 1.00 meter and shall be designed to sustain the super-imposed vehicular loading over the sewer line. The infiltration of groundwater into sewer line shall not exceed 400 liters/cm of pipe diameter per kilometer per day. Piping shall be polyvinyl chloride (PVC) or fiberglass (GRP) for diameter up to 710mm. Larger pipe over 710mm shall be GRP. Manholes shall be fiberglass or reinforced concrete with fiberglass lining or approved protective coatings. Manhole covers shall be 600mm diameter cast-iron designed for a minimum total load of 7272 kg. All sewers shall have rubber gasket joints. The desired force main velocities are from 1.00 to 1.50m/sec to prevent deposition of solids at minimum flow. 1.1.10. DESIGN OF WATER SUPPLY SYSTEM Potable water distribution system shall be designed in conformance with the applicable criteria outlined below:

1. The average potable water per capita consumptions in the area of works is assumed to be 120 liters per day.

2. The water supply and distribution network shall be designed to satisfy the maximum of the following demands:

(a) Peak daily demand

(b) Maximum hourly demand

(c) Maximum daily demand plus fire flow

3. The maximum demand to be used in the analysis of the water network shall be determined using the average daily demand multiplied by a peak flow factor as follows:

(a) Peak Daily Demand peaking factor : 3.00

(b) Maximum Hourly Demand peaking factor : 2.80

(c) Maximum Daily Demand pecking factor : 2.50

4. Fire Flow shall be determined on the greatest of the following demands:

(a) In accordance with the NFPA Codes.

(b) As specified by the FEWA/Engineer.

(c) As specified or required by local authority in the area.

(d) As minimum requirement for Industrial Zone = 1495 m³/hr.



The hydraulic analysis of the water distribution network shall be by Hardy Cross computations with computer software for such, if needed. The analysis of flow in the pipe network shall assume an appropriate ‘c’ value depending on the pipe material to be used in the Hazen-Williams formula. Critical flow analysis shall be assumed, with fire plan at the farthest hydrants from the pump. A minimum residual pressure in the main of 14 meters of head for hydrants with pumpers or 50 meters of head for hydrants without pumpers shall be assumed. The maximum velocity in the system at maximum flow shall not exceed 2.00 meters per second. Water main supplying fire hydrants shall not be less than 200mm and shall be a loop distribution system. A horizontal separation of 2.00 meters and a vertical separation of 0.50 meter shall be maintained between water and sewer lines, with the sewer line below the water line. A horizontal separation of 3.00 meters shall be maintained where a minimum of 0.50 meter vertical separation can not be achieved. At cross overs, where the vertical separation can not be maintained, the sewer line shall be encased in concrete for a minimum length of 3.00 meters on each side of the water line. 1.1.11. REINFORCED CONCRETE DESIGN Reinforced concrete design shall be carried out in accordance with BS 8110 or ACI Building Code of Practice. The use of mild steel as main reinforcement is not acceptable. Design Loadings shall be as specified on section 5.00 of this document. The main structural frame system on the LDC Building is a moment resisting reinforced concrete frame comprises of columns, beams and slabs. Concrete frame joints shall be assumed as fixed in the design of the structural systems. Grade beams shall be provided at ground level of the LDC Building. Ground slabs shall be designed as isolated slab-on-grade, with expansion joints as needed. External utilities and cables foundations including any equipment foundations shall also be of reinforced concrete, such as trenches, troughs, ductbanks. 1.1.12. DESIGN OF STRUCTURAL STEELWORK Steelwork design shall be carried out in accordance with BS 5950 or AISC Code of Practice. The design strengths used shall be those given in the Standard for the grade of steel specified but using Grade 43A or A36 as a minimum or such other grade as may be approved by the FEWA Engineer. The use of back-to-back angles in structures shall not be used.



Steel structures shall be designed such that the steel is not in contact with the soil. Base plates shall be at least 250mm higher than the finish grade level. Minimum thickness of rolled sections and built up members with the exception of cold-formed steel members shall be 6mm. Connections carrying calculated stresses, except for lacing, sag bars, and girts, shall be designed to support not less than 27 kN. All bolted connections shall have two 16mm diameter bolts each minimum. 1.1.13. EARTHING DESIGN Reinforced Concrete Frame members and structural steel members shall be tied to the main station Earthing system in line with electrical requirements. The Contractor shall provide additional galvanized reinforcement welded as a grid in foundations and floor slabs including bars with protrude tangs in columns and beam separate to the main structural reinforcement for Earthing as required. 1.1.14. DESIGN PROGRAMME The Contractor shall, within two weeks of appointment, submit to the FEWA Engineer, his detailed programme for the production of design calculations, drawings and details of the Civil Engineering and Building Works. The detailed design and drawings and full specifications for all the works to be executed shall be submitted to the FEWA Engineer for approval. A period of four weeks is to be allowed for the FEWA Engineer to review and reply to any submission by the Contractor. Sufficient time shall be allowed to enable the FEWA Engineer to check and agree any revisions, which may be necessary before the start of any part of the Works. Following approval by the FEWA Engineer, the Contractor will be responsible for submitting the calculations and drawings to the relevant local Municipality for planning approval and obtaining building permits. At present obtaining a permit takes about eight weeks. No construction will normally be permitted on Site until the relevant designs and drawings have received full approval, and building permits obtained. 1.1.15. THERMAL REQUIREMENTS All external walls shall have a coefficient of heat transfer not greater than 0.7 W/sq.m. /deg. C, and for the roofs this shall not be greater than 0.57 W/Sq.m./deg. C. Roofs shall be sufficiently dense or other wise constructed to minimize the effects of solar gain. The coefficient of heat transfer is the heat flow per square meter of surface area with a difference of 1 degree C between the indoor and outdoor air temperature. 1.1.16. FIRE RESISTANCE - BUILDING STRUCTURE The Contractor shall make provision in the design of the building structure for minimum periods of fire resistance in accordance with The British Building Regulations 1985 - Part



B - Fire B2/3/4 Fire Spread. The designation of purpose group and type to be used for the Buildings shall be 'Industrial' see Table 0.1, page 6. The minimum periods of fire resistance (hours) shall be related to the maximum dimensions, i.e., height, floor area or cubic capacity, of buildings or compartments of buildings as referred to in Table 6.1, page 32, under purpose group 'Industrial'. For calculating the maximum dimensions the following definitions shall apply:

(a) "Area", in relation to a building, means the area calculated by reference to its finished internal faces;

(b) "Basement" means a storey of which the floor is at any point more than 1.2 meters below the finished surface of the ground adjacent to it.

(c) "Floor area" means the aggregate area of every floor in a building or extension, calculated by reference to the finished internal faces of the walls enclosing the areas, or if at any point there is not such wall, by reference to the outermost edge of the floor.

(d) "Height" means the height of the building measured from the mean level of the ground adjoining the outside of the external walls of the building to the level of half the vertical height of the roof of the building, or to the top of the walls or of the parapet, if any, whichever is the higher.

1.1.17. ROADS AND SURFACING All roads shall be single carriageway, minimum 8 meters wide. However, roads within the plot area shall have 6 meters width & be made of interlocking road tiles. Design of roads and junctions shall comply with all requirements of the relevant local Municipality As a minimum the following will apply: Maximum gradient 4% (i.e. 1 in 25). Minimum horizontal curve radius: 500 meters. Vertical curves shall be designed for 150 meter line of sight at 1 meter above road surface. Minimum kerb radius at junctions shall be 10 meters. Properly designed vertical and horizontal transition curves to be incorporated in all designs. Cross-falls from carriageway centre line to be 2%. The two types of pavement are as follows: Type I Bitumen access road connected to main existing roads. Type II Interlocking concrete blocks to roads within the area, suitable for heavy

traffic Type III Gravel (Road Base) site access road



Subject to variations necessitated by compliance with the specified tests defined below, the roads and surfacing will be of thickness and types of construction shown and be suitable for the purpose of the roads and the ground conditions encountered.

Type I Thickness Tolerances Type III Sub-base (graded gravel or crushed rock) 150mm ±15mm 150mm Base (crushed rock) 150mm ±10mm 150mm Binder course (Bitumen Macadam) 60mm ±8mm - Wearing course (Dense Bitumen Macadam) 40mm ±3mm -

Type I Thickness Tolerances Sub-base (graded gravel) 150mm ±15mm Base (crushed rock) 150mm ±10mm Bedding Sand 50mm ±5mm Block 80mm ±3mm

1.1.18. TEMPORARY WORKS Temporary works, e.g., formworks, sheet piles, etc., shall be designed for the same allowable stresses and factors of safety as applicable to Permanent Works. Where appropriate, temporary over-stress may be permitted and subject to the FEWA Engineer's approval. No Temporary Works should be carried out without the approval of the FEWA Engineer. 1.1.19. SUBMISSION TIME Design information/ inputs and drawings shall be submitted to the FEWA Engineer well in advance to allow for clarification and possible modification before issue for construction. Detailed schedule of submission shall be submitted at the initial stage of the project after the award of this contract. All details required from the manufacturer or supplier or subcontractor has to be collected by the contractor and shall be submitted to FEWA Engineer after necessary checks. Contractor will be responsible to check and verify the document supplied by manufacture, supplier and subcontractors.



1.1.20. APPENDIX 1 DESIGN INFORMATION Job Ref: Sheet No. Made by:

Contract : Checked:

Date:

Subsection : Engineer Responsible:

Relevant Building Regulations and/or Design Codes : Fire resistance requirements : General loading condition : Speed : Wind loading conditions : Seismic loading conditions : Exposure conditions : Subsoil conditions : Foundation type : Material data : Other relevant information :



1.2. MATERIALS AND WORKMANSHIP



TABLE OF CONTENTS

Page 1.2. MATERIALS AND WORKMANSHIP....................................................................... 34

1.2.1. Materials.................................................................................................................. 34

1.2.2. CIRIA Guide to Concrete Construction in Gulf Region (CIRIA

Special Publication 31) ........................................................................................... 34

1.2.3. Inspection and Testing............................................................................................ 34

1.2.4. Quarries.................................................................................................................. 35

1.2.5. Site Laboratory........................................................................................................ 35

1.2.6. Testing Equipment.................................................................................................. 36



1.2. MATERIALS AND WORKMANSHIP 1.2.1. MATERIALS Standards Reference is made throughout Sections of the Technical specification to latest British Standards Codes of Practice; the Contractor may propose other National Standards and Codes for the FEWA Engineer's approval. Such approval or Codes to be used are the ones latest at the time of tendering. General All the materials that will be used for the Works shall be to the approval of the FEWA Engineer and shall conform to the relevant Codes of Standards. Where locally quarried or similar naturally occurring materials exhibit particular properties, e.g., salt contents, such properties not being catered for by the British Standards, the Contractor must supply sufficient information in English for the FEWA Engineer to consider the suitability of such an alternative material. In considering such a material, samples from other alternative sources and chemical analysis may be required. If the FEWA Engineer accepts at his discretion such a material, more stringent or different tests than those herein, may be required. The Contractor shall give to the FEWA Engineer written notice of the preparation of manufacture at a place not on the Site or any manufactured material or component to be used on the Works, stating the place and time of the preparation or manufacture so that the FEWA Engineer may make inspection at all stages of the Work and not only when the material or component is completed. The Contractor shall provide, erect and maintain proper sheds, etc., for the storage and protection of materials, etc., and for the execution of work, which may be fabricated or brought to the Site. All proprietary materials shall be used in strict accordance with the relevant manufacturer's instructions and/or recommendations. All timber used in the project for permanent and temporary works shall be obtained from forests and sources that are certified by Government Authorities to be actively carrying out a minimum 50% reforestation programme in all logging areas. 1.2.2. CIRIA GUIDE TO CONCRETE CONSTRUCTION IN GULF REGION (CIRIA

SPECIAL PUBLICATION 31)

The Contractor's attention is drawn to the specified CIRIA report. Recommendations contained in the report should be adhered to except that in the event of any discrepancies this Specification will take precedence unless authorised by the FEWA Engineer. 1.2.3. INSPECTION AND TESTING

As provided in the Conditions of Contract, the whole of the materials used in the Works shall be subject to inspection and tests as the FEWA Engineer may direct from time to time as the work proceeds. The whole cost of such inspection and tests, including the



provision and use of equipment, shall be included in the tender including the FEWA Engineer's costs. As soon as practicable after the Contract has been awarded, the Contractor shall submit to the FEWA Engineer, a list of suppliers from whom he proposes to purchase the materials necessary for the execution of the Works. Each supplier must be willing to admit the FEWA Engineer to his premises during ordinary working hours for the purpose of obtaining samples of the materials in question. Alternatively, if required by the FEWA Engineer, the Contractor shall deliver the samples of the materials to the FEWA Engineer's Office and also the contractor may request the supplier or manufacturer representative to meet FEWA Engineer at his office with prior appointment to discuss technical matters related to the project. Samples shall be taken in accordance with the relevant British Standard where applicable. Materials subsequently supplied shall conform within any specified tolerances to the quality of samples, which have been approved. The information regarding the names of suppliers may be amended at different times, as may be appropriate, but no sources of supply shall be changed without the FEWA Engineer's prior approval. 1.2.4. QUARRIES

Aggregates or fill material shall only come from quarries or borrow pits approved by the FEWA Engineer. Quarried rock must be dense and sound and must not be taken from any area of duricrust, caprock or other area of any salt concentration. The quarrying must be done selectively with scalping from the primary crusher rejected; the final aggregate must be washed and drained. Fine aggregate should wherever possible, come from crushed rock as opposed to natural sources. Once washed, aggregate must be protected from any further contamination. Aggregates on site must be stored in a bin or on an approved concrete hard standing. Bins shall be fitted with sides to prevent inter-mixing of the different aggregates and shall be provided with a solid concrete floor at least 150 mm thick. The use of beach sand is not permitted as a fine aggregate. Washed, crushed sand from proven authorised areas shall be used for making concrete and mortar. 1.2.5. SITE LABORATORY

The Contractor has to provide and maintain a material test laboratory together with and in the charge of a competent, English speaking qualified engineer who will be responsible for supervising all the tests referred to in the Civil Specification for Materials and Workmanship. The Contractor is to grant the FEWA Engineer or his representative, full access at all times to this laboratory and shall produce on demand, the full records of all tests carried out on the Site. The engineer in charge of the laboratory must be provided with a suitable vehicle to ensure access to all parts of the Works at any time. This list is a guide from which the laboratory equipment is to be chosen by agreement with the FEWA Engineer.



The Contractor shall submit for approval a detailed drawing of the accommodation proposed for the site, indicating position of equipment and facilities, before any orders are placed. 1.2.6. TESTING EQUIPMENT

Concrete cube crushing press, 200 tones capacity hydraulic operation, complete with all fittings, calibrated and tested for accuracy every three months 01 Concrete cube moulds 150 x 150 mm 24 Grout cube moulds 100 mm x 100 mm 16 Compacting factor testing equipment 01 Slump cone 02 Gammon Morgan water-in-sand gauge Chain dial balance weighing to 150 g accurate to 0.01 g and set of weights 02 Balance weighing up to 7 kg accurate to 1 g with set of weights 01 Scales weighing to 7 kg accurate to 20 g with set of weights 01 Test Sieves to BS 410 R40/3 series and R/20 series 01 set of each Oven, oil gas or electric with Temperature gauge 01 Jack, car-type 5 tonne 02 Water tank for curing concrete cubes 01 Primus stove 01 Pycnometer (from 1 kg fruit jar) 01 ASTM liquid limit device and tools 02 Polished glass plate 600 mm square and 10 mm thick 01 Digital Thermometer 0°C - 50°C (for ambient) with humidity record facility 01 Thermometer 0°C - 50°C (for concrete) 03 Thermometer 0°C - 80°C (for steel) 01 Hydrometer, long stemmed and short stemmed for particle size determination 02 of each Hygrometer 01 1000 ml graduated cylinder 02 Stop watch 01 50 ml pipette 02 500 ml conical flask 06 250 ml graduated cylinder 02 25 ml graduated cylinder 02 Proctor mould with rammer, etc., for BS 1377;Test 13 (rammer to weigh 4.5 kg and fall 45 cm) 01 300 mm steel straight edge 01 600 g sand pouring cylinder with conical funnel and tap for density determination 02 Sand jars (plastic with screw cover) 20 Calibrating container 150 mm dia. by 150 mm deep for pouring cylinder 01 Cylindrical steel core cutter 150 mm dia by 150 mm long 12 mm thick bevelled at one end 04 Steel dolly 25 mm high, 140 mm dia. wall thickness 6 mm with tip 02 Steel rammer with wood or steel handles 02 Specimen extractor and coning tool 01 Vibrating hammer (see BS 1377; Test 14) 01 Tamping plates to suit vibrating hammer 06



Auger, rod and 2 extensions fitted with adaptor for cutters 01 38 mm ID steel cutter, relieved 03 38 mm ID steel cutter, unrelieved 03 In-situ CBR apparatus including standard plunger, proving and dial, datum frame and penetration gauge etc. 01 300 mm dia. steel plate 12 mm thick 01

23 mm post-hole auger with 8 No. 900 mm rods 01

Spade 03

Pickaxe 03

Chopper 03

Chloride detecting chemical agents 03

Wet Film thickness gauges for paint 02

Electro magnetic paint film thickness tester 02

Also pestle and mortar, spatulas, wash bottles, glass bottles with glass stoppers, conical flask, evaporating dishes, crucible, tongs, rubber tubing, glass tubing, sample tins and expendable items including chemicals and other incidental equipment. Where required by the FEWA Engineer, the Contractor must provide other similar items not listed.



1.3. EARTHWORKS



TABLE OF CONTENTS

Page

1.3. EARTHWORKS.........................................................................................40

1.3.1. Earthworks .................................................................................................40

1.3.1.1. Site Clearance ............................................................................................40

1.3.1.2. Surface levels .............................................................................................40

1.3.1.3. Unsuitable Materials....................................................................................40

1.3.1.4. Excavations ................................................................................................40

1.3.1.5. Approval of Excavation ...............................................................................41

1.3.1.6. Excavation beyond True Line and Level.....................................................41

1.3.1.7. Disposal of Spoil.........................................................................................41

1.3.1.8. Filling...........................................................................................................41

1.3.1.9. Blasting .......................................................................................................42

1.3.1.10. Subsoil Improvement/ Piling.......................................................................42



1.3. EARTHWORKS 1.3.1. EARTHWORKS 1.3.1.1. Site Clearance The Contractor shall clear all areas of the Sites over which the Works are to be constructed. He shall remove all structures; debris and vegetation to sites approved by FEWA/ Local Authorities and no debris shall be deposited except on such sites. 1.3.1.2. Surface levels

Before starting any work for the LDC Building, the contractor has to take contour levels of the plot area, and a drawing for record purpose shall be submitted to the FEWA Engineer. All levels shall relate to the existing Datum. 1.3.1.3. Unsuitable Materials Where in the opinion of the FEWA Engineer, existing material has to be retained by or to support new works. If unsuitable, the Contractor has to remove such unsuitable material and replace it with an approved imported filling. 1.3.1.4. Excavations The Contractor shall carry out all excavations required for the permanent works in whatever material may be met. All excavations shall be carried out to lengths, widths, depths and profiles necessary for the construction of the Works or to such other dimensions as may be approved in writing by the FEWA Engineer. Where excavation is in unsupported open cut, the Contractor shall be entirely responsible for ensuring that the side slopes are suitable for stability. The sides of excavation in trench shall be made secure by means of adequate supports, timbering, close sheeting, timber and steel piling as required for the Works and the means adopted shall be to the satisfaction of the FEWA Engineer. The Contractor shall be entirely responsible for the sufficiency of all temporary shoring and supports to the excavations. Where excavation is to be carried out adjacent to and lower than existing structures the Contractor shall submit to the FEWA Engineer his proposals for supporting the existing works before starting excavation. The Contractor shall carry out the excavation in such a way to avoid disturbance to the surrounding ground. The Contractor shall comply with all instructions of the FEWA Engineer regarding the supporting of the sides of excavation but such compliance shall not relieve him of any of his responsibilities under the Contract for the safety of the Works and to personnel. The excavated surfaces shall be kept dry and clean by pumping or otherwise and no concrete, masonry, brickwork or other materials shall be placed or built until the surfaces are properly drained. The methods employed shall in all cases be to the satisfaction of the FEWA Engineer. And if water is removed by pumping, it shall be done such that, the material in or around the excavations will not be disturbed by the pumping. And adequate sumps are provided.



The Contractor shall submit for the FEWA Engineer’s Approval his Proposals for disposing of water arising from de-watering excavations. The Contractor shall also be responsible for obtaining approval from the Local Authorities and has to pay any fees to local authorities. Particular attention has to be given to de-watering of excavations at works in the close proximity to Coastlines or other water masses. Samples of excavated materials removed by the Contractor shall be authorized by the FEWA Engineer and stored until completion of the Works. 1.3.1.5. Approval of Excavation

When excavations, whether in open or in trench, have been accurately taken out to the profiles or dimensions required for the works, due intimation shall be given by the Contractor to the FEWA Engineer and the same shall be inspected by or on behalf of the FEWA Engineer. 1.3.1.6. Excavation beyond True Line and Level

If from any cause whatsoever excavations other than for concrete work are carried out beyond their true line and level other than at the direction of the FEWA Engineer, the Contractor shall at his own cost make good to the required line and level with concrete or other approved material and in such a manner as the FEWA Engineer may direct. If from any cause whatsoever excavations for concrete works are carried out beyond their true line and level other than at the direction of the FEWA Engineer, the Contractor shall, when directed by the FEWA Engineer, and at his own cost fill into the required line and level with concrete similar in grade to that intended to be used in the true excavation unless otherwise directed.

1.3.1.7. Disposal of Spoil

The Contractor shall remove spoil from excavations and shall place it at a dumping point designated (or approved) by the FEWA Engineer which may be in embankments, in temporary dumps, or in permanent spoil tips, according to the quality of the spoil, the need of it for filling and other circumstances, as directed by the FEWA Engineer. All unusable excess materials shall be charted out from the site area. 1.3.1.8. Filling

All fillings for the entire Site, in embankments, refilling of trenches and other earthworks shall unless otherwise specified be formed with selected materials as approved by the FEWA Engineer. The materials shall be placed in layers not exceeding 200 mm thick when loose except where otherwise specified, thoroughly compacted with fresh water to the satisfaction of the FEWA Engineer and trimmed to the levels and slopes required. The compaction of this fill shall not be less than 97%of the maximum dry density as determined by the compaction test No.13 section 4.2 of BS 1377 using the 4.5 kg rammer. Water containing a high chloride and/or sulphate content shall not be used for compaction of fill material within 5 meters of concrete.

Compaction tests shall be carried out on every layer at the rate of one test per 100 M2

area and minimum three numbers at random locations approved by FEWA Engineer.



The Contractor shall, before commencing any filling, survey and take levels over the whole of the site to be filled and shall prepare plans and sections accordingly and furnish these to the FEWA Engineer. The Contractor shall take particular care in placing and compacting filling around pipes, cables, structures and the like, and shall take such steps as may be necessary to prevent damage thereto. The Contractor shall make good any damage or defects to the Work caused by settlements, slips or falls to any excavations or embankments and shall do all necessary work to prevent or remedy the same in accordance with the Conditions or Contract. The embankments shall have a minimum gradient of 1: 4 and has to be stabilized with a stone armoring system to the FEWA Engineer's approval. All surfaces at the agreed finished levels shall be treated with a penetrating spray applied bonding agent to stop erosion, avoid dust contamination, and assist vehicular access for site works. 1.3.1.9. Blasting

The Contractor shall not make use of any explosives without the express permission in writing of the police or other authority concerned. The use and storage of all explosives in magazines shall be subject to their approval and shall be to the satisfaction of the FEWA Engineer. The Contractor shall further arrange at his own expense for the provision of safetymen for the protection of the public and others during blasting. Where blasting is permitted it shall be carried out strictly in accordance with arrangements previously agreed in writing by the FEWA Engineer. Blasting will not be permitted in close proximity to foundation, plant and equipment; in these areas other methods shall be employed. The Contractor shall submit to the FEWA Engineer for approval full details of his proposed procedure before blasting is carried out in any area. 1.3.1.10. Subsoil Improvement/ Piling

Subsoil parameters are not available. The prospective contractor shall visit the site and shall make his own assessments of the soil conditions and shall make no future claims on this account. He shall carryout soil investigation in order to establish the soil characteristics for foundation design. Improvement of the soil or piled foundations shall be necessary for the LDC building. For any external foundations such as trenches if soil type shall not suffice the soil bearing requirement, the soil shall be improved. The Contractor shall submit proposals for the approval of the FEWA Engineer. These shall include details of the proposed methods of improvement or piling works and program of testing before, during and after. The proposals shall provide details of the pattern and the areas of the site to be treated. Subsoil Improvement

The Contractor may consider improving the soil by either vibro-compaction or vibrated stone columns.



Dynamic Compaction/Consolidation shall not be permitted. The method utilized must not cause vibration to the detriment of any adjacent buildings or structures in the area of works and of the surrounding environment. All materials and workmanship shall be in accordance with the appropriate British Standards current at the time of tender, including those listed in this Specification, except that where the requirements of British Standards are in conflict with this Specification, the latter shall take precedence. All work shall be carried out generally in accordance with the principles of relevant codes of practice current at the time of tender, including those referred to in this Specification. The execution and performance of the ground treatment shall be the responsibility of the Contractor who shall, nonetheless, satisfy the FEWA Engineer that all treated ground has attained the required degree of improvement. Where appropriate, estimates of the anticipated total and differential settlement at the working load shall be given by the Contractor. The Contractor shall supply detailed and dimensioned layouts of the treatment points in duplicate for the approval of the FEWA Engineer. Such approval shall not relieve the responsibility of the Contractor for the accuracy of the drawings. Each treatment point shall have a unique reference number for record purposes. At the commencement of the Contract the Contractor shall provide a detailed method statement. This shall include a program giving full details of both type and quantity of all the plant he proposes to use, the order of carrying out the work, and where not already specified by the FEWA Engineer the detailed and dimensioned layout of the ground treatment, type and frequency of the proposed control testing, and where applicable, the anticipated ground heave after treatment. The sources of supply of materials shall be approved by the FEWA Engineer and shall not be changed without prior approval of the FEWA Engineer in writing. Rejected materials shall be immediately removed from the Site. The Contractor shall report immediately to the FEWA Engineer any circumstances, which indicates that the ground conditions differ from those described in the site investigation report. The Contractor shall satisfy the FEWA Engineer regarding the suitability, efficiency and adequacy of the equipment to be employed. The Contractor shall state the type and number of rigs he intends to use. On completion of each area of ground treatment the Contractor shall grade debris and surplus material arising from the ground treatment to leave a firm and level-working surface. On completion of the treatment to the satisfaction of the FEWA Engineer, the Contractor shall remove from the site all plant and unwanted material. The Contractor shall carry out setting out from municipality demarcation point. Immediately before treatment, the contractor shall mark each treatment position with suitable identifiable pins or markers. The Contractor shall provide and maintain benchmarks in all sides throughout the duration of the Works.



Testing Ground Treatment Definitions

a) Proof Load

A proof load is a load applied to a selected area of working foundation

to confirm that it is suitable for the load at the settlement specified.

b) Plate Test

A plate test is a loading test carried out using a plate on treated ground

essentially used as a control of workmanship.

c) Zone Test

A zone test is a loading test carried out with a slab, intended to test

bearing pressure over a wider and deeper zone than in the plate bearing test. A zone may be a full scale test of a structural member.

Supervision

All tests shall be carried out under the direction of an experienced and competent supervisor conversant with the test equipment and procedure. All personnel operating the test equipment shall have been trained in its use. Safety Precautions Safety precautions shall comply with all statutory safety requirements. Where Kent ledge is used the Contractor shall construct the foundations for the Kent ledge and any civil works, beams or other supporting structure in such a manner that there will not be differential settlement, bending or deflection of an amount that constitutes a hazard to safety or impairs the efficiency of the operation. The Kent ledge shall be adequately bonded, tied or otherwise held together to prevent it falling apart, or becoming unstable because of deflection of the supports. The weight of Kent ledge shall be greater than the maximum test load, and if the weight is estimated from the density and volume of the constituent materials, an adequate factor of safety against error shall be allowed. Where ground anchors are used the Contractor shall ensure that the load is correctly transmitted to all the tie rods or bolts. Welding shall not be permitted to extend the rod, unless it is known that the steel will not be reduced in strength by welding. The bond stresses of the rods in tension shall not exceed nominal permissible bond stresses for the type of steel and grade of concrete used. Testing Equipment

In all cases the Contractor shall ensure that when the hydraulic jack and load-measuring device are mounted the whole system will be stable up to the maximum load to be applied. Means shall be provided to enable dial gauges to be read from a position clear of the Kent ledge stack or test frame in conditions where failure in any part of the system due to



overloading, buckling, loss of hydraulic pressure and so on might constitute a hazard to personnel. The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under hydraulic pressure shall be capable of withstanding a test pressure of 1½ times the maximum working pressure without leaking. The maximum test load or test pressure expressed as a reading on the gauge in use shall be displayed and all operators shall be made aware of this limit. Preliminary Tests

The Contractor shall carry out two preliminary tests give the FEWA Engineer at least 48 hours notice of the commencement of treatment of an area for preliminary test loading. The ground treatment for the area for preliminary test loading shall be carried out in a manner similar to that proposed for the working area and using similar equipment and materials. Preparation of Ground Surface

The Contractor shall excavate for the test to the level specified. Plate Bearing Tests: The excavated surface shall be cleaned of loose material and blinded with a layer of sand not exceeding 15 mm in average thickness. Zone Tests: The excavated surface shall be cleaned of loose material and blinded with 50 mm concrete. Concrete Test Cubes The FEWA Engineer may call for test cubes to be made from the concrete used in the slab for any zone test. The cubes shall be made and tested in accordance with BS 1881. The zone test shall not be started until the concrete in the slab has attained the 28 days strength as indicated by cube crushing tests. Spread of Test Load The steel plate or the reinforced concrete slab shall be of sufficient thickness to spread the concentrated load supplied to its upper surface evenly over the base. Reaction Systems Proof loads shall be specified in the Particular Specification. The reaction for plate bearing tests may be provided by use of mobile plant on site such as the crawler crane. Where suitable plant is not available, Kent ledge or anchor shall be used. The reaction for zone tests shall be provided using Kent ledge or ground anchors.



The distance from the edge of the area to be tested to the near part of the foundation supporting the Kent ledge shall be such as to avoid interaction between the two stressed areas. The size, length and number of the anchors, or the area of the cribs and mats, shall be adequate to transmit the maximum test load to the ground in a safe manner without excessive movement or influence on the test area. The method employed in the installation of any anchors, or erection of any cribs and mats or Kent ledge, shall be such as to prevent damage to any treated areas. Loading The loading arrangement used shall be designed to transfer safely to the test area the maximum load required in testing. Full details shall be submitted to the FEWA Engineer prior to any work relating to the testing process being carried out on the Site Equipment for Applying Load The equipment used for applying load shall consist of one or more hydraulic rams or jacks. The total capacity of the jacks shall be arranged in conjunction with the reaction system to deliver an axial load to the area. The complete system shall be capable of transferring the maximum load required for the test. Measurement of Load The load shall be measured by a calibrated pressure gauge in the hydraulic system. Jacks shall be short in axial length in order to achieve the best possible stability. Sufficient attendance shall be arranged by the Contractor to ensure that axial load is maintained. The pressure gauge and jack shall be calibrated in increments appropriate to the equipment and a valid certificate of calibration shall be supplied to the FEWA Engineer. The load-measuring device may consist of a proving ring, load-measuring column, pressure cell or other appropriate system. Spherical seating shall be used in conjunction with any devices that are sensitive to eccentric loading; care must be taken to avoid any risk of buckling. Load-measuring devices shall be short in axial length in order to achieve the best possible stability. The Contractor shall arrange sufficient attendance. The load-measuring device shall be calibrated before and after each series of tests, whenever adjustments are made to the device or at intervals appropriate to the type of equipment. The loading equipment shall be capable of adjustment throughout the test to obtain a smooth increase of load or to maintain each load constant at the required stage of a maintained loading test. Three deflection gauges positioned symmetrically around the plate shall measure the movement of the plate. Each gauge shall enable readings to be made to within 0.1mm and shall be mounted on a reference frame which will not be affected by movement of the ground due to the support for the test load, weather conditions, site traffic or other such causes. The reference frame should be protected from direct impact, and also from temperature effects where appropriate.



Zone Tests

The movement of the slab shall be measured by not less than four deflection gauges positioned symmetrically around the slab. Each gauge shall enable readings to be made to within 0.1mm and shall be mounted on a reference frame which will not be affected by the movement of the ground due to weather, Kent ledge load, application of test loads, movement of site traffic or other such causes. Optical Leveling An optical leveling method by reference to an external datum shall be used to check movement of the sand supports for the Kent ledge. A precise level and staff shall be used, the level and scale of the staff being chosen to enable readings to be made within an accuracy of 0.5mm. A scale attached to the slab may be used instead of a leveling staff. At least two datum points shall be established on permanent objects or other well founded structures, or deep datum points shall be installed. Each datum point shall be situated so that only one setting up of the level is needed. No datum point shall be affected by the test loading or other operations on the Site. Where another method of leveling is proposed this shall be approved in writing. Protection of Testing Equipment Suitable tarpaulins or other protection to shield the reference beams from direct sunlight or adverse weather shall be provided to minimize the effects of temperature variations on the readings obtained. A thermometer shall be provided to record air temperature. Supervision The Contractor shall give the FEWA Engineer at least 24 hours' notice of the commencement of the test. Working Area Test a) Plate Bearing Test Three plate bearing tests and two zone tests shall be carried out. Method 1 The maximum load, which shall be applied in a plate-bearing test is 3 times the working load. The load shall be applied in at least six approximately equal increments. Method 2 The maximum load, which shall be applied to a 600mm diameter plate, is 11 t. The load shall be applied in five equal increments. General: Following each application of load the settlement shall be measured at intervals of one minute until no change is detected and then at intervals of 5 minutes. The load shall be held



for 10 minutes or until two successive readings at 5 minutes intervals are the same, whichever is the greater. The maximum load shall be held for 15 minutes or until three successive readings at 5 minutes intervals are the same, whichever is the greater. The settlement shall be measured on release of the load and again after 5 minutes. b) Zone Test The test load shall be applied in increments not exceeding 25% working load in three stages (e) To working load (e) To 200% working load (e) To 250% of working load. Incremental loading shall not be applied until the rate of settlement under the preceding load is less than 0.5mm/h, as determined by the average of readings of the deflection gauges taken at 5 minutes intervals. The test load shall be removed in stages equivalent to the loading stages and the recovery measured. Presentation of Results Within 24 hours of the completion of the test, unless otherwise directed, a summary of the results in writing shall be submitted to the FEWA Engineer. For a plate-bearing test, the summary shall give the maximum load applied, the period for which it is held, the maximum settlement recorded, and the recovery on unloading. For a zone test the summary shall give, for each stage of loading, the period for which the load was held, the load and the maximum settlement recorded. Within 7 days of the completion of the test, the completed schedule of recorded data shall be submitted to the FEWA Engineer. This shall be as specified below for a plate bearing test or a zone test as appropriate. Schedule of Recorded Data A) Plate Bearing Tests The Contractor shall provide information about the tested ground in accordance with the following schedule where applicable: (a) General - Contract identification - Date of test (b) Test Area Details - Identification of area relative to site layout drawing - Brief description of position in structure - Ground level at test position - Excavated test level (c) Treatment details - Date and time of treatment - Unexpected circumstances or difficulties



(d) Stone Columns/Compaction - Identification numbers of probes - Diameter and depth of stone columns exposed - Spacing of adjacent columns - Depth - Stone consumption (e) Test Procedure - Approximate weight of Kent ledge - Date and times of load application (f) Test Results

- Load and settlement with time reported in tabular form, and in graphical form load and settlement being plotted against time, and load against settlement

B) Zone Tests The Contractor shall provide information about the tested ground in accordance with the following schedule where applicable. a) General

- Contract identification - Date of test

b) Test Area Details

- Identification of area relative to site layout drawing - Size and position of area - Ground level at test position - Excavated test level

c) Treatment Details

- Date and time of treatment - Unexpected circumstances or difficulties Stone Columns/Compaction - Identification number of probes - Depth of treatment - Stone consumption

d) Test Details

- Weight of Kent ledge - Ground anchor details - Plan of test arrangement showing position and distances to test area of

Kent ledge supports, rafts, or ground anchors and reference frame - Jack capacity - Method of load-measurement - Dates and times

e) Test Results

- Load and settlement with time reported in tabular form, and in graphical form, load and settlement being plotted against time, and load against settlement



Completion of a Test

The concrete slab used for a zone test shall be broken up and the resulting material disposed of off the Site. If it is in a working area care shall be taken not to disturb the soil beneath the slab. Excavations to foundation level shall be carefully backfilled and compacted with suitable materials up to the general level of the Site. On completion of any test, ground anchors shall be de-stressed, and all parts, which would later cause an obstruction to the Works removed. Piling

General

All piling work is to be carried out in accordance with the recommendations of BS 8004. Piling Design, Equipment & Workmanship

Before any piling work is commenced, the Contractor shall submit to FEWA Engineer for approval, full details of the type of pile he proposes to use with all relevant dimensions, lengths, design and ultimate loads and method of construction and full details of the piling equipment and the method of carrying out the work which he intends to use. Such information shall include, where appropriate: (a) Driven Piles A full description of the piling frame, hammer, helmet and packing and of a method of handling and pitching piles and supporting them during driving and of the proposed driving procedure to give penetration to the required level and of the proposed set for the working load on the pile and the method of calculating it. If the Contractor proposes to use a vibratory driving method full details of procedures and plant shall be submitted to the FEWA Engineer for approval all other relevant data listed above shall be submitted. (b) Bored Piles A full description of the boring rig and method, methods for laterally restraining the side of the shaft, preventing the ingress of water, cleaning and inspection of the base of the pile shaft and concreting procedure for the pile. Any revisions to these proposals, which, in the light of ensuing experience appear desirable, shall also be submitted for the approval of the FEWA Engineer. Ground Conditions

When designing and installing the piles the Contractor shall take full cognizance of all available geo-technical information, including the aggressive nature of the ground and groundwater.



The Contractor shall report immediately to the FEWA Engineer any circumstances, which indicated that, in the Contractor's opinion, the ground conditions differ from those expected by him from his interpretation of the Site investigation reports. Piling Program The Contractor shall inform the FEWA Engineer each day of the program of piling for the following day and shall give three days' notice of his intention to work outside normal hours, at weekends and during public holidays. Enlarged Pile Bases Where the Contractor wishes to form a pile with enlarged base, details of the proposed method of forming the base and the materials to be used shall be submitted to the FEWA Engineer for approval. Piling near Recently Cast Piles Casings shall not be driven or piles formed so close to other piles, which have recently been cast, and which contain workable or unset concrete that a flow of concrete could be induced from or damage caused to any of the piles. Due account shall be taken during the installation of any previously installed pile group or building/services. Performance of Driving Equipment

The Contractor shall satisfy the FEWA Engineer regarding the suitability, efficiency and energy of the diving equipment. Driving Procedure Re-drive Checks Each pile shall be driven continuously until the specified or approved set and/ or depth has been reached, except that the FEWA Engineer may permit the suspension of driving if he is satisfied that the rate of penetration prior to the cessation of driving will substantially re-establish on its resumption or if he is satisfied that the suspension of driving is beyond the control of the Contractor. A follower (long dolly) shall not be used unless approved by the FEWA Engineer, in which case the FEWA Engineer will require the set to be revised to take into account the reduction in the effectiveness of the hammer blow. The Contractor shall inform the FEWA Engineer without delay if unexpected change in driving characteristics is noted. Detailed records of the driving resistance over the full length of all piles shall be taken and submitted to the FEWA Engineer within 24 hours of completion. At the start of work and in a new area of section, sets shall be taken at intervals during the last 3m of the driving to establish the behavior of the piles. The Contractor shall given adequate notice and provide all facilities to enable the FEWA Engineer to check driving resistances. Set shall be taken only in the presence of the FEWA Engineer unless he agrees otherwise. Re-drive checks, if required, shall be carried out to an approved procedure.



Final Set The final set of each pile shall be recorded either as the penetration in millimeters per 10 blows or as the number of blows required to produce a penetration of 25 mm. When a final set is being measured, the following requirements shall be met:

(a) The exposed part of the pile shall be in good condition without

(b) damage or distortion.

(c) The dolly and packing, if any, shall be in sound condition.

(d) The hammer blow shall be in line with the pile axis and the impact

(e) surfaces shall be flat and at right angles to the pile and hammer axis.

(f) The hammer shall be in good condition and operating correctly.

(g) The temporary compression of the pile shall be recorded if required.

(h) Where a vibratory method of driving is proposed, the Contractor

(i) shall obtain the approval of the FEWA Engineer for his method of deciding

(j) the final penetration of the pile.

Driving Sequence & Risen Piles Piles shall be driven in an approved sequence to minimize the detrimental effects of heave and lateral displacement of the ground. When required, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving process. When a pile has risen as a result of adjacent piles being driven, the Contractor shall submit to the FEWA Engineer his proposals for correcting this and the avoidance of it in subsequent work. Internal Drop Hammer

Where a casing for a pile without an enlarged base is to be driven by an internal drop hammer a plug consisting of concrete with a water/cement ratio not exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to ensure that this height of driving plug is maintained in the casing throughout the period of driving and in any event a plug of fresh concrete shall be added after 1½ hours of normal driving, after 3/4 hour of hard driving or, should the pile driving be interrupted, fresh concrete shall be added after ½ hour of the cessation of driving. S Repair of Damaged Pile Heads

When repairing the head of a reinforced concrete pile, the head shall be cut off square at sound concrete, and all loose particles shall be removed by wire brushing, followed by washing with water. If the driving of a pile has been accepted but sound concrete of the pile is below the cut-off level, the pile shall be made good to the cut-off level with concrete of a grade not inferior to that of the concrete of the pile.



The damaged heads of steel piles shall be removed when required by, and using a method approved by, the FEWA Engineer. Should it then be necessary to lengthen the pile to raise the head to the required level, this shall be done by adding a section in accordance with clause 7.4.6.3.4 or BS 8004. When damage to the head of pre-stressed concrete piles occurs such that some pre stressing force is lost during driving, the Contractor must satisfy the FEWA Engineer that cracking of the pile will not affect durability and that the pile can still perform satisfactorily. Should this not be possible the pile will be abandoned and measures taken, including the driving of additional piles, to meet the FEWA Engineer's requirements. Proposals for the repair of the damaged heads of pre-stressed concrete piles shall be in accordance with any recommendations of the pile manufacturer and to the FEWA Engineer's approval. The structural continuity of the pile must be preserved. Lengthening of Piles When lengthening a reinforced concrete pile, the head shall be cut off square to sound concrete, and all loose particles shall be removed by wire brushing, followed by washing with water. Joints in reinforcement shall be such that the full strength of the bar is effective across the joint. Welded joints shall be made in accordance with BS 5135 and the main longitudinal reinforcing bars in the head of the pile shall be exposed for at least 300 mm below the weld. For lap or splice joints sufficient link bars shall be provided to resist eccentric forces. If the pile is to be subjected to further driving the additional length shall be of an approved grade. Other methods of lengthening shall be subject to approval. Lengthening of a steel pile shall be carried out in accordance with clause 7.4.6.3.4 of BS 8004. Lengthening of pre-stressed concrete piles shall be in accordance with the manufacturer's recommendations and the FEWA Engineers approval. Structural continuity of the pile shall be maintained. Inspection

Prior to placing concrete in a pile casing the Contractor shall check in an approved manner that any permanent casing is undamaged, and that the casing is free from water or other foreign matter. In the event of water or foreign matter having entered the pile casing either the casing shall be withdrawn, repaired if necessary and re-driven or other action shall be taken as may be approved to continue the construction of the pile. Concrete & Reinforcement All concrete shall be in accordance with the requirements of the Concrete Works Specification. Reinforcement used for piles shall be epoxy coated. Joints in longitudinal steel bars will not be permitted. Joints in reinforcement shall be in accordance with the Concrete Works Specification above and shall be such that the full strength of the bar is



effective across the joint and shall be made so that there is not relative displacement of the reinforcement during the construction of the pile. Bored Cast-in-Place Piles Particular reference shall be made to Clause 7.4.5 of the BS 8004 with reference to bored cast-in-place piles. When required by the FEWA Engineer, the Contractor shall take from the pile excavation undisturbed soil samples in accordance with BS 5930. Such samples shall be tested in an approved laboratory. It is essential that the exposed surface of the ground on the side of the shaft should not be allowed to deteriorate due to exposure after excavation; this deterioration can take place even with lining tubes in position. To avoid this, the Contractor shall program the work such that placing of concrete in the pile shaft shall proceed without delay immediately after the FEWA Engineer has approved the excavation. If, in the opinion of the FEWA Engineer, deterioration of the ground on the side of a pile shaft occurs due to the Contractor's failure to observe the foregoing requirements, the FEWA Engineer may require the Contractor to construct replacement piles and the cost of this work, together with any associated enlargement or re-design of the pile cap, shall be borne by the Contractor. The concrete shall be brought up to a level of 150 mm minimum above the base of pile cap. The heads of the piles shall be subsequently stripped back to a level of 75mm above the base. The Contractor shall make allowance for casing all cast-in-place piles as protection from chemically aggressive ground conditions in the capillary rise zone, all to the approval of the FEWA Engineer. It must be demonstrated by the Contractor that no adverse effect on bearing capacity or settlement will result. Placing Concrete The method of placing and workability of the concrete shall be such that a continuous monolithic concrete shaft of the full cross-section is formed. The concrete shall be placed without such interruption as would allow the previously placed batch to have hardened. The method of placing shall be approved. The Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid arching of the concrete in a casing. No spoil, liquid or other foreign matter shall be allowed to contaminate the concrete. Compaction Internal vibrators shall not be used to compact concrete unless the Contractor is satisfied that they will not cause segregation or arching of the concrete and unless their use has been approved by the FEWA Engineer. Placing Concrete in Dry Borings



Measures shall be taken to avoid segregation and bleeding and to ensure that the concrete at the bottom of the pile is not deficient in grout, such measures to be approved by the FEWA Engineer. Workability of Concrete Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted. Should semi-dry mix have been approved the means of ensuring that the semi-dry concrete does not lift during extraction of the casing shall be subject to approval by the FEWA Engineer. Concrete Level When the casing is being extracted a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water or soil is exceeded and that the pile is neither reduced in section nor contaminated. No concrete is to be placed in the boring once the bottom of the casing has been lifted above the tope of concrete; it shall be placed continuously as the casing s extracted until the desired head of concrete is obtained. Adequate precautions shall be taken in all cases where excess hydraulic heads could be caused as the casing is withdrawn because of the displacement of water by the concrete as it flows into its final position against the walls of the shaft. Safety The recommendations of Section II of BS 8004 and any requirements of the FEWA Engineer to ensure the safety of the Works shall be followed. Records During piling operations, the Contractor, as required, shall submit to the FEWA Engineer a written record of the strata encountered in respect of each pile and the depth at which each pile is founded. Descriptions of the various strata shall conform fully to BS 5930. Test Piles At least two test piles shall be provided clear of the Works and shall be loaded to failure or three times the working load, prior to commencing installation of working piles. Test Loading of Working Piles The FEWA Engineer will select two working piles of each type to be tested as the work proceeds but in no case will this selection be made later than seven days after the completion of the pile. The Contractor shall arrange his program to accommodate these tests. Pile testing shall be carried out in accordance with BS 8004. The Contractor shall ensure that adequate supervision and workforce is available for the tests to be carried out on a continuous basis including night work where necessary.



Each pile that is selected for testing will be loaded to 1½ times the working load calculated

on the basis of a working concrete compressive stress of 5.25 N/mm2

. The full loading shall be monitored for a minimum of 12 hours during which time the settlement shall be recorded at 30 minutes intervals. Loading Procedure All test piles and tests on working piles shall be loaded in accordance with Clause 7.5.5.4 of BS 8004. The load shall be applied in increments of 25% of the working load up to working load and then by increments of 12½% of the working load up to the full test load. Anchorages The Contractor shall provide a reaction system for each test pile capable of applying the test loads. The distance between the test pile and the point of application of the reaction system to the ground shall not be less than either 3 meters or three test pile shaft diameters whichever is the greater. The Contractor shall not use any working pile to provide reaction for testing. Details of the anchorage system to be employed shall be submitted with the tender and the Contractor is required to ensure that the system provides a safe and stable means of applying the load. During the test loading of the pile the FEWA Engineer’s may require that load/displacement readings of the anchors be recorded for anchors close to any working pile, should any anchor be deemed to fail the Contractor should satisfy the FEWA Engineer that the performance of any adjacent piles is not affected. Measurement of Load The load shall be applied to test piles through a calibrated load cell or proving ring capable of reading to an accuracy of 5 tons. Measurement of Settlement Settlement shall be measured in accordance with BS 8004 using a reference beam and 2 No dial gauges reading to an accuracy of not less than 0.025mm. The use of reference wires shall not be permitted. Total settlement under test load shall not exceed 25 mm. Residual settlement shall not exceed 15 mm. Test Records In addition to the records of boring the Contractor shall be responsible for compiling full pile test records including graphical records for submission to the FEWA Engineer within 7 days of completion of each test.



1.4. CONCRETE WORKS



TABLE OF CONTENTS

Page 4. CONCRETE WORKS ........................................................................................... 60

4.1. GENERAL............................................................................................................... 60

4.1.1. Standards ............................................................................................................... 60

4.1.2. Materials - General.................................................................................................. 60

4.1.3. CIRIA Guide to Concrete Construction in the Gulf Region (CIRIA

Special Publication 31) ........................................................................................... 60

4.1.4. Inspection and Testing............................................................................................ 60

4.1.5. Quarries.................................................................................................................. 61

4.2. CONCRETE........................................................................................................... 61

4.2.1. Cement ................................................................................................................... 61

4.2.2. Admixtures.............................................................................................................. 62

4.2.3. Cement Testing ...................................................................................................... 62

4.2.4. Storage of Cement ................................................................................................. 63

4.2.5. Aggregate................................................................................................................ 63

4.2.6. Aggregate Storage.................................................................................................. 64

4.2.7. Quality and Testing................................................................................................. 64

4.2.8. Fine Aggregate........................................................................................................ 65

4.2.9. Coarse Aggregate................................................................................................... 65

4.2.10. Potential Alkali Reactivity ........................................................................................ 66

4.2.11. Sulphate and Chloride Content............................................................................... 66

4.2.11.1. Sulphate............................................................................................................. 66

4.2.11.2. Chloride.............................................................................................................. 67

4.2.12. Water ...................................................................................................................... 68

4.2.13. Porosity................................................................................................................... 68

4.3. Steel For Reinforced Concrete............................................................................... 68

4.3.1. Concrete Cover to Reinforcement ......................................................................... 69

4.3.2. Storage of Reinforcement ...................................................................................... 69

4.4. Design, Ancillaries, Placing, Protection.................................................................. 69

4.4.1. Mix Design .............................................................................................................. 70

4.4.2. Test Cubes ............................................................................................................. 71

4.4.3. Water/ Cement Ratio.............................................................................................. 71



4.4.4. Workability .............................................................................................................. 71

4.4.5. Compaction and Slump Tests................................................................................ 71

4.4.6. Concrete Mixing: ..................................................................................................... 72

4.4.7. Transfer of Concrete .............................................................................................. 72

4.4.8. Placing of Concrete ................................................................................................ 72

4.4.9. Temperature Records ............................................................................................ 73

4.4.10. No Partially Set Material to be used........................................................................ 73

4.4.11. Compaction of Concrete ........................................................................................ 74

4.4.12. Concreting in Adverse Weather Conditions and High Ambient

Temperatures ......................................................................................................... 74

4.4.13. Concreting at Night or in the Dark .......................................................................... 75

4.4.14. Curing and Protection............................................................................................. 75

4.4.15. Construction Joints................................................................................................. 77

4.4.16. Preparation of Surfaces to Receive Concrete ....................................................... 77

4.4.17. Water stops ............................................................................................................ 77

4.4.18. Expansion and Contraction Joints.......................................................................... 78

4.4.19. Concrete Formwork................................................................................................ 79

4.4.20. Forms for Exposed Concrete Surfaces ................................................................. 80

4.4.21. Forms for Non-Exposed Concrete Surfaces ......................................................... 80

4.4.22. Preparation of Forms for Concreting...................................................................... 80

4.4.23. Concrete Tolerances.............................................................................................. 81

4.4.24. Removal of Formwork ............................................................................................ 81

4.4.25. Formwork below Water Level................................................................................. 82

4.4.26. Precast Concrete ................................................................................................... 82

4.4.27. Concrete Returns ................................................................................................... 82

4.4.28. Exposed Surfaces .................................................................................................. 82

4.4.29. Fair Finish ............................................................................................................... 83

4.4.30. Integral Waterproofing ............................................................................................ 83

4.4.31. Holes and Fixings ................................................................................................... 83

4.4.32. Grouting of Base Plates, etc................................................................................... 83

4.4.33. Protective Coatings ................................................................................................ 83



1.4. CONCRETE WORKS 1.4.1. GENERAL 1.4.1.1. Standards Reference is made throughout to mainly British and some American Standards and Codes of Practice. The Contractor shall use the ones current at the time of tendering, equivalents will not be permitted. 1.4.1.2. Materials - General All material to be incorporated in the Works shall be to the approval of the FEWA Engineer and conform to the relevant Standards. Where locally quarried or similar naturally occurring materials exhibit particular properties, e.g., salt contents, such properties not being catered for by the Standards, the Contractor must supply sufficient information in the English language for the FEWA Engineer to consider the suitability of such an alternative material. In considering such a material, samples from other alternative sources and chemical analysis may be required. If the FEWA Engineer accepts at his discretion such a material, more stringent or different tests than those herein, may be required. The Contractor shall give to the FEWA Engineer written notice of the preparation or manufacture at a place not on the Site of any manufactured material or component to be used on the Works, stating the place and time of the preparation or manufacture so that the FEWA Engineer may make inspection at all stages of the work and not only when the material or component is completed. The Contractor shall provide, erect and maintain proper sheds and temporary structures, for the storage and protection of materials, and for the execution of work, which may be fabricated or brought onto the Site. All proprietary materials shall be used in strict accordance with the relevant manufacturer's instructions and/or recommendations. 1.4.1.3. CIRIA Guide to Concrete Construction in the Gulf Region (CIRIA Special

Publication 31)

The Contractor's attention is drawn to the above CIRIA report. Recommendations contained in the report should be adhered to except that in the event of any discrepancies this Specification will take precedence unless authorized by the FEWA Engineer. 1.4.1.4. Inspection and Testing As provided in the Conditions of Contract, the whole of the materials used in the Works shall be subject to inspection and tests as the FEWA Engineer may direct from time to time as the work proceeds. As soon as practicable after the Contract has been awarded, the Contractor shall submit to the FEWA Engineer, a list of the suppliers from whom it proposes to purchase the materials necessary for the carrying out of the Works. Each supplier must be willing to admit the FEWA Engineer to its premises during the supplier's working hours for the



purpose of obtaining samples of the materials in question. Alternatively, if required by the FEWA Engineer, the Contractor shall deliver the samples of the materials to the FEWA Engineer's Office. Samples shall be taken in accordance with the relevant British or American Standard where applicable. Materials subsequently supplied shall conform within any specified tolerances to the quality of samples, which have been approved. The information regarding the names of suppliers may be amended at different times, as may be appropriate, but no sources of supply shall be changed without the FEWA Engineer's prior approval. 1.4.1.5. Quarries

Aggregates shall only come from quarries or borrow pits approved by the FEWA Engineer. Quarried rock must be dense and sound and must not be taken from any area of duricrust, caprock or other area of any salt concentration. The quarrying must be done selectively with scalpings from the primary crusher rejected; the final aggregate must be washed and drained. Fine aggregate should wherever possible, come from crushed rock as opposed to natural sources. Once washed, aggregate must be protected from any further contamination. Aggregate on Site must be stored in a bin or on an approved concrete hard standing. Bins shall be fitted with sides to prevent inter-mixing of the different aggregates and shall be provided with a solid concrete floor at least 150 mm thick. Beach sand shall not be used, except with the prior permission of the FEWA Engineer. 1.4.2. CONCRETE

The provisions of the following clauses shall apply to all sites mixed and ready mixed concrete. Compliance with the British Ready Mixed Concrete Association's Code for ready-mixed concrete and BS 8110 is required for equipment and personnel. 1.4.2.1. Cement

The type of cement to be used for each item of concrete shall be as indicated on the drawings. The cement used throughout the Works shall be obtained from manufacturers approved in writing by the FEWA Engineer and shall be appropriate conform to the following type: (a) Ordinary Portland cement (OPC) Cement for concrete structure shall be Portland cement complying with BS 12 but containing not less than 4% and not more than 13% proportion by weight of tri-calcium aluminates. Cement shall be of recent manufacture and shall be used within 3 months from date of production. Total cementitious contents in the concrete mix shall be limited to avoid excessive risk of

thermal and shrinkage cracking. It shall always be in the range of 400-480Kg/m3

unless otherwise approved by FEWA Engineer.



(b) Moderate Sulphate Resisting Portland cement (MSRPC) Cement complying with BS 12 but containing not less than 4% and not more than 8% proportion by weight of tri-calcium aluminates, or cement complying with ASTM C150 Type II. In either case the cement shall not contain more than 2.7% proportion by weight of sulphur trioxide. (c) Sulphate Resisting Portland cement (SRPC) complying with either BS 4027

or ASTM C150 Type V. Cement shall comply with the following requirements: (i) The acid-soluble alkali level measured as (Na20 + 0.658 K20) shall not exceed

0.6% by weight. (ii) The heat of hydration shall not exceed 75 calories per gram at 7 days when tested

in accordance with ASTM C186.

(iii) The specific surface shall be not greater than 325 m2

/kg and not less than 225

m2

/kg when tested as described in BS 4550 Part 3, Section 3.3. (iv) The temperature of the cement shall not exceed 45°C at the time of incorporation

into a concrete mix. High Alumina Cement shall not be used in any part of the Works. The Contractor's attention is drawn to the practice of certain manufacturers of grinding Sulphate Resisting Portland Cement to a high degree of fineness with consequent reduction of setting time and difficulty of achieving a satisfactory finish. The Contractor shall take all necessary measures including the use of approved additives to ensure that the finished concrete complies fully with this Specification. In the case of Sulphate Resisting Portland Cement the Contractor shall demonstrate to the Engineer that the chemical composition of the proposed cement has minimum tri-calcium aluminates content in order to provide high sulphate resistance. 1.4.2.2. Admixtures

No admixtures shall be used without the approval of FEWA Engineer and unless suitability of admixtures proven in trial mixes in presence of FEWA Engineer. FEWA Engineer may approve the use of non-corrosive admixtures in concrete according to circumstances. Concrete admixtures shall comply with requirements of BS 5075 'Concrete admixture'. Admixtures containing chlorides will not be permitted in the mix under any circumstances. Retarders and workability agents based on lignosulphates may be permitted subject to the FEWA Engineer's approval based on trial mixes. 1.4.2.3. Cement Testing

All cements shall be certified by the manufacturers as complying with the requirements of the appropriate Standard identified in Clause 2.1. Before orders are placed the Contractor shall submit details of the proposed supplier(s) together with such information on the proposed methods of transport, storage and certification so that the FEWA Engineer may satisfy himself that the quantity and quality required can be supplied and maintained



throughout the construction period. Where necessary the FEWA Engineer may require further representative samples of proposed cement to be taken and forwarded to an approved laboratory for analysis and testing before the source is approved. Having obtained the FEWA Engineer's approval of the source(s) of supply, transport, storage and certification of the cement the Contractor shall not modify or change the agreed arrangements without obtaining the FEWA Engineer's permission. In addition to routine test certificates which are to be supplied by the manufacturer to show the average result of sample tests made on batches of cement produced at the Works, each consignment delivered to the Site shall be sampled and tested by the manufacturer and the results of the standard 3 day and 7 day tests shall be submitted promptly to the FEWA Engineer. The Contractor shall ensure that the arrangements for the storage of the cement on the Site as hereinafter specified are sufficient for the segregation and identification of each consignment until the results of the sampling and testing referred above are available. In addition to the tests described above, the FEWA Engineer may test each consignment of cement on arrival on the Works and also after it has been stored on the Works prior to use. The FEWA Engineer may also ask for any further tests, which he may consider advisable or necessary to ascertain if the cement has deteriorated in any manner during transit or storage. No cement shall be used until the FEWA Engineer has passed it as satisfactory. 1.4.2.4. Storage of Cement The cement shall be delivered to the Site of the Works in bulk or in sound and properly sealed bags and while being loaded or unloaded and during transit to the concrete mixers, whether conveyed in vehicles or by mechanical means, must be protected from the weather by effective coverings. Efficient screens are to be supplied and erected where directed by the FEWA Engineer to prevent wastage of cement during strong winds. If the cement is delivered in bulk, the Contractor shall provide at his own cost approved silos of adequate size and number to store sufficient cement to ensure continuity of work and the cement shall be placed in these silos immediately after it has been delivered to the Site. Approved precautions shall be taken during unloading to ensure that the resulting dust does not constitute nuisance. If the cement is delivered in bags, the Contractor shall provide at his own cost perfectly waterproofed and well-ventilated sheds having a floor of wood or concrete raised at least 300 mm above the ground. The sheds shall be large enough to store sufficient cement to ensure continuity of work and each consignment of each type of cement shall be stacked separately therein to permit easy access for inspection, testing and approval. On delivery at the Works the cement shall at once be placed in these sheds and shall be used in the order in which it has been delivered. All cement shall be used within three months of the date of manufacture. 1.4.2.5. Aggregate



The Contractor shall obtain approval of proposed aggregate sources, and shall select suitable aggregate and samples of sand and stone for specified testing before obtaining aggregate. Laboratory tests shall be made at regular intervals to confirm the suitability of aggregate. 1.4.2.6. Aggregate Storage Aggregate shall be stored in concrete-based bins or on stages to prevent intermixing and the inclusion of dirt and foreign materials. Each size of aggregate shall be stored separately. The storage bins shall be covered to provide shade and reduce contamination from wind blown sand. Storage bins shall be emptied and cleaned regularly. 1.4.2.7. Quality and Testing Aggregate shall be free from earth, clay, loam and soft, clayey, shells or decomposed stone, organic matter and other impurities and shall be hard to dense. The percentage of hollow shells shall not exceed 3% by mass retained on a BS 2.36 mm sieve. Aggregate to be used in the construction of structures for retaining aqueous liquids shall comply with Clause 6.2.2 of BS 8007. Aggregate shall conform in all respects with BS 882 and 1201. The following shall apply when tested in accordance with BS 812: Aggregate crushing value shall not exceed 20% Water absorption shall not exceed 2%. The following criteria shall be ascertained by testing to assess the suitability of aggregate:

(a) Grading.

(b) Magnesium sulphate soundness.

(c) Specific gravity and water absorption.

(d) Clay, silt and dust content.

(e) Organic impurities.

(f) Sulphate and chloride content.

(g) Crushing value; alternatively 10% fines value or impact value as

(h) Approved.

(i) Elongation and flakiness.

(j) Potential alkali reactivity.

(k) Los Angeles abrasion.

(l) Drying shrinkage in accordance with BRS Digest 35.

(m) Moisture content.



The frequency of tests (a) to (l) shall be in accordance with the following table: Frequency Once Per Period of Days Test Ref. Aggregate Sand

(a) 1 1

(b) 30 (c) 7 7 (d) 1 1 (e) 30 30 (f) 3 1 (g) 7 7 (h) 3 3.5 (i) Initial Only Initial Only (j) 30 - (k) Initial Only Initial Only (l) 1 (morning) 1 (morning) The tests shall be carried out in accordance with British and ASTM standards as may be applicable and the results shall comply with the limits given therein, or as otherwise stated therein. Grading tests shall be carried out daily or per 100 m3 whichever is the more frequent when concrete is being produced on a regular basis or beforehand when production is irregular. The combined grading of aggregate shall be constant. The percentage passing any sieve size as determined by approved trial mixes shall be the targets grading for all concrete of that type. The combined grading of the Works concrete shall not vary by more than 4% from that target. If the estimated or measured combined grading of the permanent works concrete does not meet this requirement then a new trial mix shall be prepared for approval. 1.4.2.8. Fine Aggregate Fine aggregate shall be capable of passing through a 5 mm BS test sieve and shall be graded so that when mixed with the coarse aggregate and cement a concrete of maximum density is produced. It shall not contain appreciable amounts of flaky or elongated particles. Crushed sand may be added to natural sand in approved proportions in order to achieve the required grading. Crushed sand alone shall not be used without approval. The amount of material passing a 75 microns BS 410 fine sieve when tested in accordance with BS 812 (wet-sieving method) shall not exceed 3% by mass. When subjected to five cycles of the soundness test specified in ASTM C88, fine aggregate shall show a loss not exceeding 10% when magnesium sulphate solution is used. Beach sand shall not be used except with the prior permission of the Engineer. Sand for mortar shall comply with BS 1198, 1199 and 1200. 1.4.2.9. Coarse Aggregate



Coarse aggregate shall be totally retained on a 5 mm BS test sieve; the grading shall be within the limits prescribed in BS 882 Table 1 so that when mixed with the approved fine aggregate and cement a workable concrete of maximum density is produced. The densities of the classes of concrete shall be as approved after tests have been carried out on the Site. The amount of material passing a 75 microns BS 410 fine test sieve when tested in accordance with BS 812 (wet-sieving method) shall not exceed 1% by mass. Coarse aggregate shall be tested for drying shrinkage characteristics in accordance with BRS Digest No.35. When subjected to five cycles of the soundness test specified in ASTM C88, coarse aggregate shall not show a loss exceeding 10% when magnesium sulphate solution is used. The flakiness and elongation indices of the predominant size fractions in each single-sized coarse aggregate, determined in accordance with BS 812, shall not exceed 20% and 35% by mass respectively. Material for use in concrete, which is subject to abrasion and impact, shall comply with the test requirements of BS 812 and the specifications of BS 1984 and BS 882. 1.4.2.10. Potential Alkali Reactivity Aggregate shall not contain any materials that are reactive with alkalis in the aggregate itself or in the cement, the mixing water or in water in contact with the finished concrete or mortar in amounts sufficient to cause excessive localized or general expansion of the concrete or mortar. The Contractor may initially assess an aggregate source by testing in accordance with ASTM C289. If potential reactivity is indicated, then mortar bar tests in accordance with ASTM C227 shall be carried out and the results shall comply with the limits given in ASTM C33 for overall effect on the permanent works mixes, before use of the aggregate is approved. 1.4.2.11. Sulphate and Chloride Content

1.4.2.11.1. Sulphate

The following levels of acid-soluble sulphates (SO3) are indicative and are subject to the overriding limit for the mix: - Course aggregate 0.4% by mass - Fine aggregate 0.4% by mass - Water used for mixing and curing of concrete 500 mg/l The total estimated sulphate content (SO3) of the mix including that present in the cement should not exceed 3.7% by mass of cement in the mix.



In addition, regular tests to BS 1881: Part 124 shall be made on the hardened concrete to determine the total sulphate content, which shall not exceed 4% by mass of cement in the mix.

1.4.2.11.2. Chloride

The acid-soluble chloride as NaCl (Cl x 1.65 = NaCl) level in aggregate as a percentage by mass shall not exceed the limits given in the following table: Concrete Course Aggregate Fine Aggregate Type Mass with OPC or MSRPC 0.10% 0.10% Reinforced with OPC or MSRPC 0.05% 0.10% Mass with SRPC 0.05% 0.05% Reinforced with SRPC 0.02% 0.05% The acid-soluble chloride as NaCl (ClX1.65 = NaCl) level in water used for mixing and curing of concrete shall not exceed 600 mg/l. The total estimated content, as a percentage by mass of the cement in the mix shall not exceed the following limits: (a) For reinforced concrete 0.4% if made with OPC or MSRPC (Type II) 0.1% if made with SRPC (Type V) (b) For mass concrete 1.0% if made with OPC or MSRPC 0.2% if made with SRPC In addition, weekly tests for chloride content shall be made on the hardened concrete, to BS 1881: Part 124. The following values are acceptable: (c) For reinforced concrete made with OPC or MSRPC. 95% of the test results less than 0.40% NaCl by mass of cement and no result

greater than 0.50% NaCl by mass of cement. (d) For reinforced concrete made with SRPC. 95% of the test results less than 0.1% NaCl by mass of cement and no result

greater than 0.14% NaCl by mass of cement. (e) For mass concrete made with OPC or SRPC. 95% of the test results less than 1.0% NaCl by mass of cement and no result

greater than 1.30% NaCl by mass of cement. (f) For mass concrete made with SRPC. 95% of the test results less than 0.2% NaCl by mass of cement and no result

greater than 0.25% NaCl by mass of cement. In the event that the SRPC used contains a proportion by mass of tri-calcium aluminates which approaches that required for MSRPC (4 - 8%), then approval may be sought for an appropriate adjustment of the relevant chloride content limits.



1.4.2.12. Water The Contractor shall make his own arrangements and obtain approval for the provision of fresh water for the manufacture and curing of concrete. Water to be used for mixing and curing concrete and mortar shall be fresh and free from sediment and dissolved or suspended matter, which may be harmful and shall comply with the requirements of BS 3148. Water samples from the intended source of supply shall be taken for analysis before any concrete work is commenced, and at intervals throughout the duration of the Contract. If the samples are unacceptable, the Contractor shall either change to a new supply or take steps to improve the existing source, as approved. The acid-soluble sulphate (SO3) content shall not exceed 500 mg/l, and the acid-soluble chloride as NaCl (Cl x 1.65 = NaCl) content shall not exceed 600 mg/l. Tests to establish the contents shall be carried out at monthly intervals. The Contractor shall state the sources from which it proposes to obtain water and submit evidence to show that an adequate supply is assured. 1.4.2.13. Porosity Samples of hardened concrete shall be tested weekly for Porosity according to Rilemanmd water permeability to DIN 1048. 1.4.3. STEEL FOR REINFORCED CONCRETE

Steel reinforcement, used in reinforced concrete shall comply with BS 4449, BS 4460, BS 4482, BS 4483 and BS 8110 as appropriate. All reinforcement shall be with minimum yield

strength of fy = 465 N/mm2.

The Contractor shall furnish the FEWA Engineer with copies of the manufacturer's certificates of tests for the steel reinforcement to be supplied. The FEWA Engineer may, however, order independent tests to be made at the Contractor's expense for every 100T in each shipment; two samples of each bar size shall be tested as follows: - Chemical composition to be tested to BS 4449 - Mechanical properties test including tensile properties, elongation, bend test and re-

bent test - Cross section area and mass test - For detailed curves, diagrams and tables, reference is made to DIN 1045 or the

relevant BS, both latest editions Any steel, which does not comply in all respects with the appropriate foregoing specifications, will be rejected. The Contractor shall prepare reinforcement shop drawing & bar bending schedules based on the approved structural Drawings in accordance with BS 4466, BS 8110 and BS 8007 recommendations. Bends and cranks in reinforcement bars shall be carefully formed in accordance with the approved Drawings and appropriate standards.



The number, size, form and position of all steel reinforcing bars, ties, links, stirrups and other parts of the reinforcement shall be in exact accordance with the Drawings and they shall be kept in the correct position and with the required cover without displacement during the process of compacting the concrete in place in a manner approved by the FEWA Engineer. The Contractor shall provide all necessary distance pieces and space bars at its own cost to maintain the reinforcement in the correct position. The type of distance piece shall be subject to the approval of the FEWA Engineer. Only approved concrete or plastic spacers shall be used to achieve the required minimum thickness of concrete cover to reinforcement. Concrete spacers shall have non-metallic ties. Timber blocks for wedging the steel off the formwork will not be allowed. Any ties, links or stirrups connecting the bars shall be taut so that the bars are properly braced and the inside of hooks and bends shall be in actual contact with the bars around which they are intended to fit. All reinforcement shall be blast cleaned with proprietary grit immediately prior to concreting. 1.4.3.1. Concrete Cover to Reinforcement The minimum concrete cover for durability to any reinforcing bar shall be: All concrete below ground 75 mm Upper surfaces of foundations and ground slabs 75 mm Above ground - exposed faces of slabs, beams, Walls and columns 50 mm Internal faces of columns, walls and beams 50 mm Internal faces of slabs 30 mm Note: (i) Cover noted is to the outside bar regardless of whether it is main or secondary

reinforcement. (ii) For concrete exposed to brackish water, brine and seawater splashing 100 mm

cover is required. (iii) For water or liquid retaining structures, the cover should be reviewed in conjunction

with design, to limit the allowable crack widths. Linings will also need to be applied. 1.4.3.2. Storage of Reinforcement

Steel reinforcement shall be stored in an approved manner raised above ground, on a concrete slab, under cover and racked for protection from aggressive elements and physical damage. If reinforcement is to be cut and bent on Site it shall be delivered in straight lengths. Any reinforcement arriving on Site already bent for whatever reason may be ordered off the Site. 1.4.4. DESIGN, ANCILLARIES, PLACING, PROTECTION



1.4.4.1. Mix Design Concrete shall consist of cement; graded aggregate and water thoroughly mixed, compacted and placed to provide strengths as required for its various use. To ensure the durability of concrete, the recommendations of BS 8110, Table 3.2 and Clause 6.2 ("very severe") should be followed with regard to minimum cement contents. All structural concrete shall have a 28 days characteristic strength of 40N/mm2. Minimum cement content shall be 420kg/m3 and maximum cement content shall be limited to 480 kg/m3. In no case shall the water/cement ratio be greater than 0.42. The maximum temperature of the fresh concrete shall be 30 0 C. The minimum temperature of the fresh concrete shall be 9 0 C. With reference to the above limits, the Contractor shall submit for the FEWA Engineer's approval a schedule of classes of concrete giving type of cement, maximum aggregate size, minimum cement content and 7 and 28 day works cube strengths for grades indicated on the Drawings. The works cube strengths in the schedule referred to above are for concrete made into 6 inch cubes, cured and tested in accordance with BS 1881. The 7 days strengths are to be used only as a guide to the 28 days strengths. When concrete is cured at a higher mean temperature than that specified in BS 1881, the strengths are to be greater than those obtained above. Before the placing of any concrete, the Contractor shall submit to the Engineer and obtain his approval of:

a) Details of the materials the Contractor proposes to use including results of tests specified by the FEWA Engineer.

b) Results of preliminary cube and other tests justifying the design of concrete mixes of various classes.

c) The Contractor's proposed method of ensuring that concrete work complies in all respects with this specification and is placed in all cases without interruption.

The Contractor is to be responsible for ensuring that, at all times during the Contract, the quantity and quality of the constituents and placing of concrete are as approved by the FEWA Engineer. Trial mixes using representative materials shall be carried out under full-scale conditions using the Contractor's proposed method subject to the FEWA Engineer's approval. Testing shall be carried out in accordance with BS 1881.



The trial mixes shall be carried out on three days within one week during which the workability will be recorded and six cubes made on each of the days. Of each set of six cubes, three will be crushed at 7 days and the other three at 28 days. A trial mix will be approved when the requirements of BS 5328 are satisfied. 1.4.4.2. Test Cubes

Test cubes from random batches of concrete to be used in the Works are to be made in sets of six, or otherwise as approved, as and when required by the FEWA Engineer but with a minimum of 6 cubes per 25 m3. The Contractor is to include in its Tender for all charges in connection with concrete cube testing in approved independent laboratory. The testing of cubes shall generally be in accordance with the requirements of BS 5328. Test cubes shall be made, cured, stored, transported and tested in compression in accordance with BS 1881. The method of compacting cubes by vibration shall be subject to the approval of the FEWA Engineer. 1.4.4.3. Water/ Cement Ratio A simple and convenient system of accurately varying the water supply to the concrete mixers shall be installed with gauges marked so that the amount fed into the mixer may easily be ascertained. The water/cement ratio for the various classes of concrete shall be determined by the trial mixes and in no case shall the water/cement ratios used be allowed to exceed by more than 5% those determined by the trial mixes and shall not exceed 0.42 at any time. Efficient means shall be provided for determining the moisture content of the sand and coarse aggregate at all times. The Contractor has to include details of his proposed method of control of the water/cement ratio. Subject to approval by the FEWA Engineer, this method is to be used in the trial mixes under full-scale conditions. 1.4.4.4. Workability

The Contractor shall carry out compaction factor, slump or other workability tests for every truck delivery during concreting of permanent Works in order to relate the degree of workability of the mix with the numerical value obtained during the trial mixes. 1.4.4.5. Compaction and Slump Tests

Compaction factor tests shall be carried out in accordance with the procedures laid down in BS 1881 Part 103, except when otherwise specified or approved by the FEWA Engineer. Slump tests in lieu of compaction factor tests shall only be adopted where specifically approved by the FEWA Engineer. When used the slump tests shall be carried out in accordance with the procedure laid down in BS 1881 Part 102. The acceptable slump is normally 75±25mm.



1.4.4.6. Concrete Mixing: All concrete shall be of Ready mix concrete except where specifically permitted by the Engineer in writing. Ready mix concrete supplier shall be subject to the approval of FEWA. Supplier should have the computerized batching plant. The contractor has to submit mix design and arrange for trial mix from the approved supplier at his own expenses. The use of truck mixed concrete shall not be permitted. Batched materials shall be measured out within the following tolerances and shall be discharged into the mixer, without loss. Cement ±2% of the mass of the cement in the batch Aggregate ±2% of the mass of each aggregate in the batch Water ±2% of the mass of water added to the batch Admixtures ±5% of the amount to be added to the batch The concrete ingredients, classification and time of addition of water to the mix shall be recorded on delivery note of each concrete batch supplied to site. Delivery trucks will not be permitted to discharge any concrete that has been batched for more than 60 minutes. Where hand mixing is approved by FEWA for non-structural elements, the cement content of the mix shall be increased by at least 15%. 1.4.4.7. Transfer of Concrete The concrete shall be discharged from the mixers and transported to the Works by means which shall be approved by the FEWA Engineer and which shall prevent contamination (by dust, rain or other causes), segregation or loss of ingredients. The means of transportation shall ensure that the concrete is of the required workability at the point and time of placing. 1.4.4.8. Placing of Concrete The concrete shall be placed in the positions and sequence previously approved by the FEWA Engineer. Except where otherwise directed, concrete shall not be placed unless the FEWA Engineer or his representative is present and has previously examined and approved the positioning, fixing and condition of reinforcement and any other items to be embedded, and the cleanliness, alignment and suitability of the containing surfaces or formwork.



The concrete shall be deposited as nearly as possible in its final position without re-handling or segregation and in such a manner as to avoid displacement of the reinforcement, or other embedded items or formwork. Wherever possible bottom opening skips shall be used. Where chutes are used to convey the concrete their slopes shall not be such as to cause segregation, and suitable spouts or baffles shall be provided where necessary. Concrete shall not be dropped through a greater height than 1.5m except with the approval of the FEWA Engineer who may order the use of bunkers and the turning over of the deposited concrete by hand before being placed. Concrete shall not be placed in standing water or running water unless so specified or approved. The Contractor may at its own option and expense with the prior approval of the FEWA Engineer place concrete by pumping. Concrete pumps shall be operated by mechanically applied pressure and shall produce a continuous stream of concrete without air pockets. When pumps are used, the discharge velocity shall be regulated by suitable baffles or hoppers, where necessary to prevent segregation or damage and distortion of the reinforcement, embedded items and formwork, caused by impact. When pumps are used on large or complicated pours a standby pump shall be provided. Precautions shall be taken to avoid depositing water or grout in the Works during starting up operations or in flushing or clearing the pipeline. The pipeline shall pass its own length of concrete in not more than 20 minutes. When pumping is completed the concrete remaining in the pipeline if it is to be used in the works is to be ejected in such a manner that there will be no contamination of the concrete or separation of the ingredients. After this operation the entire equipment is to be thoroughly cleaned. The Contractor shall submit to the FEWA Engineer full details of the design of the concrete mix to be used for pumping. The Contractor must ensure that there is no variation of the water/cement ratio of pumped concrete due to the ingress of water at the pumping plant. The concrete shall not be subject to any form of vibration between 2 hours and 24 hours after placing. No mechanical activity to recently placed concrete such as scrubbing will be permitted until 36 hours after placing of fresh concrete. The kickers for RCC walls and periphery columns shall be 150 mm high and shall be cast monolithically with the raft with PVC water stopper placed in the middle of the kicker. 1.4.4.9. Temperature Records The Contractor shall supply suitable maximum/minimum digital thermometers and record the temperatures of the ambient shade adjacent to all parts of the Works where concrete is being placed and record the temperature of concrete supplied to the site for every truck. The maximum temperature of fresh concrete shall not exceed 300 C. Any truckload of concrete exceeding the specified temperature will be rejected by the FEWA Engineer. 1.4.4.10. No Partially Set Material to be used



All concrete and mortar must be placed and compacted within 60 minutes of its being mixed unless otherwise approved; no partially set material shall be used in the Works. In the case of ready mixed concrete, the concrete shall be transported in truck mixers complying with the requirements of BS 4251. Concrete shall be discharged from the delivery vehicle within 1 hour of loading subject to the approval of the FEWA Engineer. 1.4.4.11. Compaction of Concrete The concrete shall be fully compacted throughout the full extent of the layer and shall be brought up in level layers of such depth that each layer is readily and properly incorporated with the layer below by the use of internal vibrators. Whilst concrete is being placed in position it shall be compacted in such a manner as to produce a dense uniform mass, special care being exercised to ensure that fresh concrete is properly incorporated with adjacent unset concrete and that the concrete between and around the reinforcement and adjacent to the forms is free from voids and other imperfections. During the placing of concrete for reinforced work a competent steel fixer shall be in constant attendance, to adjust and correct the position of the reinforcement if necessary. Except where otherwise permitted by the FEWA Engineer, concrete shall, during placing, be compacted by vibrators of a type approved by the FEWA Engineer. The vibrators shall be suitable for continuous operation. They shall be disposed in such a manner that the whole of the mass under treatment shall be adequately compacted at a speed commensurate with the supply of concrete from the mixers. Vibration is to continue until the concrete being placed is fully compacted and all air bubbles have been expelled. Care must be taken that segregation of mortar and aggregate by excessive vibration is avoided. Vibration is not to be applied directly, or through the reinforcement, to sections or masses of concrete, which have hardened or after the initial set has taken place. Vibration must not be used to make the concrete flow in the formwork. Underwater concrete shall be placed with minimum disturbance of the water. Running water and wave wash shall be controlled. The concrete grade used and the mix design shall provide for good flowing ability. Tremie pipes, bottom-dump skips or other approved placing equipment shall be used. Segregation shall be avoided. Placing shall be commenced in an approved section and continued to completion. The tremie pipe shall be buried in the concrete and the pipe must not be emptied until the pour is complete. If a bottom-dump skip is used, the contents shall be covered by canvas or similar before lowering into the water. The doors shall be opened when the skip is resting on the bottom with no tension in the support cable, and the skip shall be lifted gradually so that the concrete flows out steadily. 1.4.4.12. Concreting in Adverse Weather Conditions and High Ambient

Temperatures



No concreting will be allowed to take place in the open during storms or heavy rains. In places where such conditions are likely to occur the Contractor shall arrange for adequate protection of the materials, plant and formwork so that work may proceed under proper cover. Where strong winds are likely to be experienced additional precautions shall be taken to ensure protection from driving rain and dust and the evaporation of water from the concrete surface. The temperature of the concrete at the time of placing should not exceed 30°C. In hot weather it will be necessary for the Contractor to take precautions, such as spraying coarse aggregate with cold water; painting all plant and equipment white; shading of aggregate stockpiles, water and machinery; protecting moulds and mixed concrete from the direct rays of the sun; cooling of the mix constituents, machinery, reinforcement and moulds; and restricting transportation time to a practical minimum. The addition of crushed ice into the concrete mix in lieu of water will be necessary during the summer months. During placing suitable means shall be provided to prevent premature stiffening of the concrete placed in contact with hot surfaces. All concreting areas, formwork and reinforcement shall be shielded from the direct rays of the sun, protected from drying winds, and sprayed with clean water when necessary. . The FEWA Engineer may withhold approval of commencement of concreting until he is satisfied that full and adequate arrangements have been made. 1.4.4.13. Concreting at Night or in the Dark Where approval has been given to carry out concreting operations at night or in places where daylight is excluded the Contractor shall provide adequate lighting at all points where mixing, transportation and placing of concrete are in progress. 1.4.4.14. Curing and Protection Immediately after compaction and for at least 7 days thereafter concrete shall be protected against harmful effects of sunshine, drying winds, cold, rain or running water. During this period the measures given below shall be taken to prevent the loss of moisture from the concrete and to minimize thermal stresses caused by the difference in temperature between the surface of the concrete and the core of the concrete mass. No other methods shall be employed except with the FEWA Engineer's approval. Where water is to be used for curing concrete it shall be fresh water of concreting quality in accordance with this Specification. Unless otherwise agreed by the FEWA Engineer curing is to be carried out as follows: Horizontal surfaces:

(i) Polythene sheeting shall be placed in contact with the concrete surface immediately after finishing and held in position to prevent moving air from evaporating water from the surface.

(ii) After final set has taken place, the polythene shall be replaced with wet Hessian, which shall then be covered with polythene held down as above.

(iii) After at least 7 days the Hessian and polythene shall be removed and an aluminized or white pigment resin based curing compound sprayed on the surface. The rate of application shall be strictly in accordance with the manufacturer's



recommendations. The particular compound and method of application are to be approved by the FEWA Engineer.

(iv) The Hessian shall be kept wet at all times.

(v) Concrete shall be shaded at least for the first 7 days and as long as possible thereafter as instructed by the FEWA Engineer.

(vi) Where specific surface textures are required, e.g. brush finishing on road slabs then alternative methods may only be employed with the approval of the FEWA Engineer.

Vertical Surfaces: (i) Immediately after stripping, the member shall be wrapped with wet Hessian and then covered with polythene, which shall be held firmly in place to prevent wind drying of surfaces. The Hessian shall not be allowed to dry out.

(ii) After an initial curing period of at least 7 days the Hessian and polythene

may be removed and the concrete surface sprayed with an aluminized or white-pigmented resin based curing compound as an alternative to retaining the Hessian and polythene in place for at least another 7 days. Where timber or other insulating formwork is used it must either be struck as specified or it shall be left in place until such time after the temperature peak is reached as the FEWA Engineer may direct. Air circulation along the exposed faces of concrete shall be prevented during the curing period. All joints, which have to be filled with sealing compound, or surfaces formed as construction joints, shall be protected in a manner, which will ensure that no curing compound is placed on the bonding surface, e.g., by placing wet Hessian. The protection is to ensure proper curing of the joint surface and adjacent concrete and is to remain in place until the joint surface is sealed or for the periods specified. All concrete shall be protected from anything likely to interfere with the process of setting. No load of any kind shall be imposed upon any concrete members after the removal of the struts until the concrete is thoroughly set and hardened and has reached the specified 28 days strength. Where curing membranes are used they shall be compatible with waterproofing or other materials that may subsequently be applied to the surface of the concrete. All concrete liable to be affected by running water or wave action shall be adequately protected from damage during the setting period and all temporary protective works shall be to the satisfaction of the FEWA Engineer. The Contractor's attention is drawn to the particular importance of proper and adequate curing. Failure to carry out satisfactory curing can lead to cracking in the concrete. This in turn can lead to salt attack of the reinforcement and consequential failure of the structure.



If in the opinion of the FEWA Engineer cracks occur in a structure, which in his judgment are severe enough to affect the structure, the Contractor shall cut out and replace the defective concrete at his own cost. 1.4.4.15. Construction Joints The position and arrangement of construction joints shall either be shown on the drawing or agreed with FEWA Engineer in line with applicable standards before concreting. Concreting shall be carried out continuously up to construction joints. The Contractor shall allow for working beyond the ordinary working hours where necessary in order that each section of concrete may be completed without any laps while the work is in progress. All construction joints shall be shuttered square to the work. Keyways shall be formed in all horizontal and vertical construction joints except where ordered by the FEWA Engineer to be omitted. To ensure bond between old and new concrete at construction joints, surfaces of the old concrete shall be cleaned of all defectives, latency, oil, grease, dirt, loose concrete, etc., and shall properly be roughened by chipping, hammering or other techniques to the aggregates to provide sufficient key for the two layer. Before casting the new concrete, the old concrete surfaces shall be thoroughly wetted and saturated with water, commencing at least 12 hours prior to casting of the new concrete. Bonding agent shall be applied as recommended by manufacturer. Shear key joints shall be provided in vertical construction joints, the reinforcement of such key joints shall be subject to the approval of FEWA Engineer. All construction joints in trenches, basements, oil water tanks, etc., shall contain PVC water bar as specified and the reinforcement shall be arranged accordingly. 1.4.4.16. Preparation of Surfaces to Receive Concrete Before concrete for reinforced concrete work is deposited, a blinding concrete of 100 mm minimum thickness of grade M20/20 shall be placed over the ground below the underside level of the reinforced concrete to form a hard even and leveled surface on which to construct the latter. Where shown on the Drawings or directed by the FEWA Engineer, concrete placed against rock shall be dowelled by means of steel reinforcing bars anchored into the rock. The Contractor shall drill holes of the necessary diameter into the rock to receive the anchors. Each hole shall be flushed out with water, filled with 1:1 sand-cement mortar and the anchor bar inserted to the full depth of the hole. Immediately before depositing concrete on or against a surface of rock, masonry, brickwork, old concrete or the like, the following preparation shall be carried out. All lose material shall be removed and the surface washed down; all water emerging at the surfaces shall be stopped as far as possible or suitably channeled or piped away from the Works. 1.4.4.17. Water stops Water stops are to be 250 mm minimum width and manufactured from moulded natural or synthetic rubber, neoprene or UPVC and are to be a type and quality approved by the



FEWA Engineer. Where used in works liable to hydrocarbon contamination or containing oil, the water stops shall be appropriately resistant. The water stops shall form a continuous network and jointed strictly in compliance with manufacturer's recommendations. 1.4.4.18. Expansion and Contraction Joints Expansion and contraction joints shall be provided at intervals not exceeding 5 m to allow for all movements and to minimize shrinkage and thermal strains in the concrete. The number and locations of all joints has to be shown on the working Drawings. Contraction joints shall be formed as deliberate planes of discontinuity in the concrete structure. To form such a joint the face of concrete slab or block first formed shall be painted with two coats of approved rubber bitumen paint before the adjoining slab or block is concreted. The exposed edges of joints shall be sealed with an approved poly-sulphide rubber sealing compound to BS 4254 or other approved oil, ultra-violet and water resistant sealing compound. Expansion joints shall be formed in the same way as contraction joints but in addition a resilient flexible non-decaying fibrous material impregnated against attack from insects and water shall be supplied and placed in the joint to provide freedom for two adjacent concrete slabs or blocks to expand. The exposed edges of the joints shall be sealed with an approved poly-sulphide rubber sealing compound to BS 4254 or other approved oil and water resistant sealing compound. After sealing the expansion joints, joints shall be protected by durable covers (e.g. powder coated metal covers, aluminium strips, etc.,) approved by FEWA Engineer. Preformed joint filler shall be of the required thickness within a tolerance of ±1.5 mm. It shall be 25 mm less in depth than the thickness of the slab, within a tolerance of ±3 mm and in suitable lengths, each not less than 1.2 m. Holes to accommodate dowel bars shall be accurately bored or punched out to be a sliding fit on the dowel bars. The material comprising joint filler shall be of approved quality such that it can be satisfactorily installed in position at the joint. Joint filler materials shall comply with the following tests: (a) Weathering Test Test specimens shall be exposed to a temperature of 60°C for 7 days and shall then be immersed in water at room temperature for 24 hours. The temperature shall then be lowered gradually to 0°C ± 1°C which temperature shall be maintained for 4 hours. Then the temperature of the specimen shall be raised gradually to between 30°C and 40°C. After five cycles have been completed, the specimens shall be removed from the water and allowed to stand in air at room temperature for 48 hours. The specimen will have passed this test if it then shows no sign of disintegration. (b) Compression and Recovery Test Specimens, which have been subjected to the weathering test, shall be given 3 applications at 24 hour intervals of a constant load, sufficient to compress the material to



50% of its thickness before test. The load to attain this compression shall be not less than 0.14 MN/m2 nor more than 10.4 MN/m2 for material to be used for carriageway joints and not less than 0.14 MN/m2 nor more than 0.4 MN/m2 for material to be used in building joints. At the end of the series of applications and removals of the load, the material shall recover to at least 70% of its thickness before test within a period of 2 hours after the release of the last loading. (c) Extrusion Test Test specimens measuring 115 x 115 mm shall be tested before weathering by compressing to 50% of the thickness before test with 3 edges restrained. The amount of extrusion of the free edge must not exceed 6 mm. The manufacturers shall supply certificates that the material has complied with the foregoing tests. Dowel bars for expansion joints in concrete shall consist of mild steel complying with the relevant requirements of BS 4449. Dowel bars shall be straight, free from burred edges or other irregularities and shall have their sliding ends sawn. The sliding half of each dowel bar shall be painted with a thin coat of bond breaking compound and the end of this half shall be provided with a close fitting plastic or waterproof cardboard cap at least 100 mm long, the end 20 mm of which shall be filled with a disc of joint filler or a pad of cotton waste. Bond breaking compound for dowel bars shall consist of a bitumen paint containing 66 percent of 200 pen bitumen blended hot with 14 percent light creosote oil with the addition, when cold, or 20 percent solvent naphtha. It shall in no way retard or otherwise affect the setting of concrete. Where a design joint occurs in a water retaining structure, or where otherwise ordered, the joint shall be made watertight by the provision of a continuous water stop strip fixed across the joint. Special care shall be taken to ensure that the concrete is well worked against the embedded parts of the strips and is free from honeycombing. Precautions are to be taken to protect any projecting portions of the strips from damage during the progress of the works and, in the case of rubber and plastic, from light and heat. For joints in water retaining structures or continuously submerged in water, the joint is to be normally constructed as specified. This joint is to be further protected/ sealed with a joint bridge comprising water resistant plasticized PVC strip with polyester felt edges fixed with epoxy resin adhesive. 1.4.4.19. Concrete Formwork

Design and construction of formwork shall be in accordance with BS 8110 and or BS 5975, item 6.9-part1. The Contractor shall submit for the approval of the FEWA Engineer details of the method and materials proposed for shuttering each section of the work. Details of all proposed wrought shuttering and shuttering to produce special finishes shall be submitted to FEWA Engineer for approval before any materials are brought to the site. If the FEWA Engineer so requires, samples of formwork shall be constructed and concrete placed so that the proposed methods and finish effect can be demonstrated. Proprietary formwork support systems and materials shall be used for all Works. Forms shall be constructed from sound materials of sufficient strength, properly braced, strutted and shored to ensure rigidity throughout the placing and compaction of the



concrete without visible deflection. Forms shall be so constructed that they can be removed without shock or vibration to the concrete. Internal ties shall be of metal and capable of removal without permanent injury to the concrete. No part of any metal tie or spacer remaining permanently embedded in the concrete shall be nearer than 75 mm to the finished surface. All timber for formwork shall be selected quality and shall have a

flexural stress “sigma b” minimum 10 N/mm2

. All metal ties shall be cranked and incorporate a puddle flange water stop. All joints shall be close fitting to prevent leakage of grout and at construction joints the formwork shall be tightly secured against previously cast or hardened concrete to prevent stepping or ridges to expose surfaces. Formwork shall be constructed to provide the correct shape, lines and dimensions of the concrete within the tolerances specified hereafter. Due allowance shall be made for any deflection which will occur during the placing of concrete within the forms. Panels shall have true edges to permit accurate alignment and provide a neat line with adjacent panels and at all construction joints. All panels shall be fixed with their joints either vertical of horizontal unless otherwise specified or approved. When chamfers are to be formed the fillets shall be accurately cut to size to provide a smooth and continuous chamfer. Shop drawings for scaffolding have to be submitted to FEWA Engineer for approval before starting any formwork. 1.4.4.20. Forms for Exposed Concrete Surfaces Forms for all permanently above ground concrete surfaces shall be such as to ensure no surface irregularities greater than 3 mm and, in the case of reinforced concrete, the full cover to steel reinforcement shall be maintained. Wrought shuttering shall be used such as to produce a smooth and even surface free from perceptible irregularities, and tongued and grooved planed boards or plywood or steel forms shall have their joints flush with the surface. The Contractor shall make due allowance for the renewal and/or repair of shuttering for which more than one use is intended. Suitably sized chamfers shall be provided to all exposed arises unless otherwise agreed by the FEWA Engineer. Rebate features 15 x 15 mm shall be provided at all construction joints. Alignment of all rebates shall be absolutely straight. The Contractor's attention is drawn to the protective coating requirements of Clause 4.36. The whole formwork surfacing, finish and alignment shall be such that the protective coating finish shall not be impaired or defective due to the formwork utilized. 1.4.4.21. Forms for Non-Exposed Concrete Surfaces Where the finished surface of concrete is not to be permanently exposed, the forms may be constructed of plain; butt jointed sawn timber unless otherwise directed by the FEWA Engineer. In mass concrete, surface irregularities may be permitted but in reinforced concrete construction the surface shall be true and the full cover to the reinforcement shall be maintained at all points. The tolerances for the finished concrete dimensions shall not be exceeded. 1.4.4.22. Preparation of Forms for Concreting

Before concrete is placed, the form shall be thoroughly cleaned and freed from sawdust, shavings, dust or other debris by hosing with water, compressed air or other approved



means. Temporary openings shall be provided to assist in removal of the water and rubbish. After cleaning, the forms shall be coated with approved shutter release oil, which shall not be allowed to run on to reinforcement or other embedded steelwork. All formwork shall be inspected and approved by the FEWA Engineer before concrete is placed within it though this shall not relieve the Contractor from the requirements as to soundness, finish and tolerances of the concrete specified elsewhere. 1.4.4.23. Concrete Tolerances

The line grades and dimensions of the concrete shall conform to those detailed on the Drawings within the following tolerances: - a) Overall dimensions and levels : -3 mm to +3 mm b) Column sizes : -0 mm to +3 mm c) Beam sizes : -0 mm to +3 mm d) Slab thickness : -0 mm to +3 mm e) Wall thickness : -0 mm to +3 mm f) Foundations and R.C. walls and slab below ground level : -5 mm to +10mm g) Vertical lines out of plumb: -3 mm in 5 m but not exceeding 5 mm in total h) Formwork for beam soffits shall be erected with an upward camber of 5 mm per 3

m of span. i) The gap under a 3 m long straight edge placed on any plane surface or edge in any

direction shall not exceed 3 mm. 1.4.4.24. Removal of Formwork Removal of formwork shall be approved by FEWA Engineer at site, and shall be removed in such a manner as will ensure that no damage to freshly cast concrete occurs. No forms shall be removed until the concrete has attained sufficient strength to carry the stress induced in the concrete by such removal. If required the contractor shall provide evidence of the same, which is satisfactory to FEWA Engineer. Centers and props may be removed when the member being supported has attained sufficient strength to carry itself and the load to be supported on it with a reasonable factor of safety. External loading shall not be applied until the concrete has reached its characteristic cube strength. The following table is a guide to the minimum periods, which must elapse, between the completion of the concreting operations and the removal of shuttering. Notwithstanding this table no prop or shuttering shall be removed without the permission of the FEWA Engineer and such permission shall not relieve the Contractor of its responsibilities for the safety of the structure. The cost of rectifying damage arising form the premature removal of forms shall be the contractor’s risk. Minimum stripping and striking times O.P.C. or S.R.P.C. M.S.R.P.C. Vertical sides of beams, walls, columns, lift not exceeding 1.2 m 24 hours 36hours



Vertical sides of beams, wall, columns, lift exceeding 1.2 m 36 hours 60 hours Soffits of main slabs (props left under) 7days 8 days Soffits of beams, frames etc (props left under) 14days 14days Removal of props - beams and main slabs and other work 21 days 21 days 1.4.4.25. Formwork below Water Level

Formwork below or between tides has to be so fitted and caulked that the flow of water is prevented. The formwork is to be so restrained and the rate of placing of concrete so arranged as to prevent uplift and consequent deflection of the shutters due to buoyancy. Alternatively, the Contractor may submit to the FEWA Engineer proposals for recasting all or any portion of the underwater work including any proposed joints, which will be accepted provided they are compatible with the design criteria for those Works. 1.4.4.26. Precast Concrete

Concrete members specified to be fabricated as pre-cast concrete units shall be fabricated with concrete of the specified class placed into a grout-tight mould. If so required the mould shall be laid on a vibrating table and vibration applied while the concrete is placed. The FEWA Engineer's approval shall be sought concerning which faces of the concrete member shall be the exposed faces and the specified surface finish shall be applied to them. With the approval of the FEWA Engineer the Contractor may be permitted to pre-cast members which were specified to be constructed in-situ and in such cases the Contractor shall carry out the work as described above. Generally members which are structurally dependent on a rigid fixing with the adjoining structures will not be permitted to be constructed by recasting. 1.4.4.27. Concrete Returns

The Contractor shall send weekly to the FEWA Engineer a return, which shows the quantities of cement and the number of mixings of concrete used in each section of the Works including temporary Works. The quantities of cement used for all purposes in the Works shall bear a proper relation to the quantities of cement tested and concrete mixed and approved by the FEWA Engineer. In the event of any difference from the approved design, the measures at the mixers for cement shall be adjusted as ordered by the FEWA Engineer. 1.4.4.28. Exposed Surfaces

The finished faces of all concrete work shall be sound, solid and free from honeycombing, excrescences and blemishes.



Plastering of defective concrete as a means of making good will not be permitted. Surfaces showing minor porosity shall, if the FEWA Engineer so approves, be rubbed down with cement and sand mortar of the same richness as the concrete immediately after the removal of formwork. All such remedial work shall be carried out in accordance with the FEWA Engineer's instructions at the Contractor's expense. The materials for filling holes shall be compatible with and to the approval of the manufacturer(s) of the final coating materials. 1.4.4.29. Fair Finish

Where the surface of the concrete is specified to be "fair faced" as distinct from wrought finish, it shall be rubbed smooth with a corborandam stone immediately on removal of the shuttering and while the concrete is green and all small holes shall be stopped with cement mortar of such a mix as to render the stopping invisible. 1.4.4.30. Integral Waterproofing

Integral waterproofing of concrete shall be achieved where indicated on the Drawings by the use of an admixture approved by the FEWA Engineer. 1.4.4.31. Holes and Fixings Where holes or fixings for equipment are required these shall be setout to a tolerance of plus or minus 3 mm unless otherwise directed. Holes and pockets shall be formed square to the formwork. Permanent liners and formers shall not be used unless of expanded metal or similar material. When metal liners are used specified concrete cover should be maintained. Threaded inserts and cast-in-bolts shall be fixed square to the formwork by a temporary bolt or nut and the concrete cast around them. All threads shall be cleaned of grout and projecting parts protected from rusting with bituminous paint. All boltholes shall be cleaned, prepared, primed and filled with a proprietary non-shrink cementatious material.

1.4.4.32. Grouting of Base Plates, etc.

Spaces between base plates and foundations for columns, plant, machinery, etc., shall be grouted with an approved non-shrinking grout or epoxy grout. The space between the base plate and foundations shall be completely filled with grout and must provide maximum support over the complete area of the base plate and possess good impact resistant qualities. Proprietary brands of grout shall be used. The type of grout used and method of application shall be to the approval of the FEWA Engineer, in particular air holes shall be provided where necessary in base plates to eliminate all possibility of any entrapped air pockets. If required the Contractor shall demonstrate to the FEWA Engineer by means of samples and tests that the proposed grout is satisfactory. 1.4.4.33. Protective Coatings

External protection to all foundations, substructures and all concrete structures in contact with soil has to be applied with an approved SBS modified bituminous membrane of minimum 4 mm thickness. The above bituminous membrane has to be protected with an approved protection board of bituminous type in accordance with the manufacturer's



instructions. The membrane is to be continued to the finished ground level and terminated in the tuck in grove made in the concrete and sealed with bituminous sealant. All exposed concrete surfaces above tanking membrane tuck-in level shall be coated with an approved penetrating silicone water-repellant, chloride resistant coating and subsequently over coated with an approved compatible two coats smooth finish acrylic

paint system. Sample panels of minimum area 10 m2

shall be made on finish concrete to prove the finish quality and enable the color to be selected. Only these panels finally approved may be included in the Works.



5. BUILDING WORKS



TABLE OF CONTENTS

Page 1.5. BUILDING WORKS....................................................................................88

1.5.1. Building Works ...........................................................................................88

1.5.1.1. External Walls ............................................................................................88

1.5.1.2. Internal Walls..............................................................................................88

1.5.1.3. Vertical Cladding ........................................................................................88

1.5.1.4. Block Walls ................................................................................................89

1.5.1.5. Painting of Internal Surfaces ......................................................................90

1.5.1.6. Ceramic Wall Tiles.....................................................................................91

1.5.1.7. Plaster Finish .............................................................................................91

1.5.1.8. Cement Wash............................................................................................91

1.5.1.9. External Plastering .....................................................................................91

1.5.1.10. Painting of External Surfaces.....................................................................92

1.5.1.11. Roofs..........................................................................................................93

1.5.1.12. Deck Roofs ................................................................................................93

1.5.1.13. Roof Finishes .............................................................................................93

1.5.1.14. Concrete Flooring.......................................................................................94

1.5.1.15. Preparation of Flooring...............................................................................94

1.5.1.16. Cement/Sand Screed ................................................................................95

1.5.1.17. Epoxy Resin Screed ..................................................................................95

1.5.1.18. Acid/Alkali Resisting Ceramic Tiles ...........................................................96

1.5.1.19. Ceramic Floor & Wall Tiles........................................................................96

1.5.1.20. Floor Expansion Joints...............................................................................96

1.5.1.21. Stairs, Steps, and Thresholds ...................................................................96

1.5.1.22. Suspended Ceilings ...................................................................................97

1.5.1.23. Concrete Ceilings.......................................................................................97

1.5.1.24. Plumbing ....................................................................................................97

1.5.1.25. Sanitary Fittings..........................................................................................98

1.5.1.26. Metalwork Generally ...................................................................................98

1.5.1.27. Windows ....................................................................................................98

1.5.1.28. Doors and Frames.....................................................................................99

1.5.1.29. Locks and Door Furniture ........................................................................100



1.5.1.30. Timber ......................................................................................................100

1.5.1.31. Painting of Woodwork and Timber...........................................................101

1.5.1.32. Oiling Hardwood.......................................................................................102

1.5.1.33. Wood Screws ..........................................................................................102

1.5.1.34. Hand railing and Balustrades ...................................................................102

1.5.1.35. Access Ladders .......................................................................................102



1.5. BUILDING WORKS 1.5.1. BUILDING WORKS 1.5.1.1. External Walls The external walls of the buildings shall be constructed of insulated hollow concrete blocks within the reinforced concrete frame. The block work shall be plastered externally and painted with UV resistant multi layer polyurethane paint system with texture finish, and finished internally with acrylic emulsion paint or other paint system as specified. External block walls shall be double skin with 50 mm thick thermal insulation with rock wool or other thermal insulation board. Factory made insulated concrete blocks also shall be used for the construction of external walls. Provision shall be made in the wall construction to permit the structural framework to deflect laterally under wind/seismic conditions without overstressing the block work panels. 1.5.1.2. Internal Walls

All internal walls shall be constructed with hollow concrete blocks and shall conform to the requirements of this Specification. All internal walls of basement shall be constructed with solid concrete blocks. Internal wall finishes shall be as specified in finishing schedule. 1.5.1.3. Vertical Cladding

Cladding where required should be PVDF2 coated profiled sandwich panel (insulated aluminium sheet construction) suitable for long maintenance-free life, and adequate to withstand the climatic and site pollution conditions. Samples of the proposed cladding shall be submitted to the FEWA Engineer for approval. No orders shall be placed with Manufacturers until without the approval of the FEWA Engineer. Both skins of all metal wall cladding shall be made from profiled aluminium sheet. The outside surface shall be protected by a system of abrasion resistant colorfast coatings. The inner face of the internal skin shall have a factory applied finish of approved color. Any cut edges and holes resulting during manufacture or erection should be treated with corrosion resistant coating. Care shall be taken to prevent bi-metallic corrosion occurring by the use of heavy PVC adhesive tape between the sheeting and supporting rails, and by the use of stainless steel fasteners and fixings. The PVC tape shall overlap the edges of the sheeting rails by at least 15 mm along their full length. Fasteners and trim shall be stainless steel. Spacing and location of fasteners and supporting rails shall be as recommended by the manufacturer.



Care shall be taken to remove swarf from holes drilled in sheeting and steelwork as the work proceeds, to prevent rust stains, and damage to the PVC tape. Cladding sheets or flashing found to be soiled or damaged should be replaced. Insulation shall be phenloic foam having a BS 476 class 1 Surface spread of Flame rating. Exposed flashings used in conjunction with wall cladding shall be purpose made to the same specification as the external cladding. Flashings shall be fixed with stainless steel self-tapping screws with plastic coated heads or 'pop' rivets, at not more than 450 mm centers. 1.5.1.4. Block Walls

The concrete blocks, mortar, ties, damp-proof courses, and all related materials shall be to the approval of FEWA Engineer. All concrete blocks shall be properly cured. The thickness and proposed insulation to suit the 'U' value specified of block work, method, and standard of workmanship, and all related construction details shall be to the satisfaction of the FEWA Engineer. The strength of the masonry block wall shall conform to BS 6073 part 1 or other national standards acceptable to FEWA Engineer. The walls shall not allow the passage of water or moisture into the building. The walls shall be provided with all necessary horizontal and vertical damp-proof courses, cavity trays, and flashings. The damp-proof courses, trays and flashings shall consist of aluminium cored bitumenized hessian covered sheet or similar approved material complying with the requirements of an approved National Standard. All external walls shall possess coefficient of heat transfer ('U' value) not greater than 0.8 W/m2 degrees C. Blocks shall comply with an appropriate National Standard approved by the FEWA Engineer. The average compressive strength of the blocks shall not be less than 8.0 N/mm2 (80 Kg/cm2) and the minimum compressive strength of any individual block shall not be less than 6 N/mm2 (60 Kg/cm2). No block shall be set in place within 28 days of casting. Blocks cast on any one day shall be stored together in a group marked with the date of casting by a suitable notice. The Contractor shall provide a specimen panel of fair-faced block work for approval by the FEWA Engineer. Thereafter all fair-faced block work shall conform to this approved standard. Separate samples of each type of block taken at random from site delivery, or at the block yard, shall be deposited for approval by the FEWA Engineer. The FEWA Engineer will reject any load or part load should he find a block or blocks to be below the required strengths, uncured, under or over the required size, damage or to have any other defect, which he may consider detrimental to the work concerned. Specially shaped blocks required to form proper bonding and which cannot be made in a standard block making machine may be made in approved wooden mould. Where specifically shaped blocks are manufactured they shall be solid. Where in-situ concrete work is to be cast on top of hollow block walling, the Contractor shall form the top course of the walls in solid blocks and shall provide two layers of building paper to form slip joints in such locations where it is intended to provide separation.



Wall ties shall be an approved stainless steel butterfly type with split ends and shall be of size 200/150 mm x 25 mm. Wall ties shall be used in all external cavity walls at centers not exceeding 450 mm in the vertical and 450 mm on the horizontal, and shall be staggered, spacing of ties shall be closed up at all openings. Gun shot method of fixing will not be allowed to fix any ties. Dowel anchors shall be provided at all junctions between block work walls and beams and columns. They shall be spaced at centers not exceeding 450 mm. Mortar for block work shall be cement mortar in proportions 1:3 (Portland cement to sand). All mortar shall be mixed in a power driven mixer and in addition all materials shall be screened before mixing to remove lumps. The Contractor may use plasticizer with mortar subject to the approval of FEWA Engineer, provided it is used in accordance with the manufacturer's instructions. Sand for use in mortar shall have chemical content limits as specified for sand used in concrete. Sand shall be stored in walled compounds with a concrete floor. The concrete blocks, mortar and water used for mixing, shall be free of harmful soluble salts, which could form excessive efflorescence. Blocks shall be thoroughly wetted prior to laying. Blocks shall be well buttered with mortar before being laid and joints shall be thoroughly flushed up from the top as the work proceeds and not faced in afterwards. Block work shall be carried up in uniform manner and no one portion shall be raised more than 1 m above the remainder at one time. All vertical angles, corners, and the like shall be kept strictly true and square and the whole properly bonded together and leveled. Cavities shall be kept clear of mortar dropping by lifting boards. Finished block work shall be protected from direct sunlight and from the drying effects of winds for at least 7 days. The Civil Contractor shall make provision for pockets and chases, etc., required in connection with plumbing, electrical and other similar installations. Chasing after plastering will not be permitted. Fair-faced block work shall be kept perfectly clean as the work proceeds and no rubbing down of wall surfaces will be allowed. The walls to be fair-faced shall have the vertical joints pointed flush and the horizontal joints struck pointed as the work proceeds. Particular attention shall be paid to each course being level so that the finished appearance is first class. Horizontal damp-proof courses shall be provided underneath all block work walls and shall be bedded on mortar. Vertical damp-proof courses shall be provided at all doors and window reveals. Block work walls shall not exceed 15 m2 shall be restricted with intermediate stiffener beams and columns. 1.5.1.5. Painting of Internal Surfaces

All internal rendering and plastering, block work and fair-faced concrete excluding chemical areas shall be painted with one primer coat and two finishing coats of exterior highest quality emulsion. The surfaces to be coated shall be dry, dust, and oil free. Ceiling covered



by false ceiling also to be coated with one coat of white emulsion primer and wall portion inside the false ceiling portion shall be coated with internal painting system. Chemical areas shall be coated with chemical resistant paint, suitable to the location. In preparation work prior to painting hygroscopic stopping/filler materials shall not be used. Maximum air and/or surface temperature for application should not exceed +40deg C, and relative humidity should in no case exceed 85%. Moisture content of the surface shall not exceed 5% in any case. 1.5.1.6. Ceramic Wall Tiles

Samples of all ceramic wall tiles are to be submitted to the FEWA Engineer for his approval. The size, thickness, and material should match the floor tiles. Glazed facing tiles, mortar bed and adhesive system, pointed with high quality, cement based, water resistant grouting similar to the grouting material specified for ceramic floor tiles. Colour of tiles shall be to the discretion of FEWA Engineer. The dados are to be provided with 100 mm high covered tile bases. The tops of the dados and 'external' corners are to be finished with round edges tiles. 1.5.1.7. Plaster Finish

The type of plaster employed and its method of application shall be to the satisfaction of the FEWA Engineer. All workmanship for cement plastering work shall follow the recommendations laid down in the relevant standards (BS 5492). The plastering shall be securely bonded to the block work and shall be free from crazing and efflorescence. Approved pre-mixed plaster systems should be used for which only water need be added. Plastering shall be done in two coats with total thickness not exceeding 20mm. The Key coat shall be 6 mm thick, the floating coat 14 mm thick. The Key coat and floating coats shall consist of one part Portland cement to three parts sand. Sand shall be two part of sieved black sand and one part of washed white sand. Any admixtures required by FEWA Engineer shall be used to improve the quality of finish. Waterproofing admixtures shall be used for all external plastering works and wherever the wall surface may be subject to water contact. Exposed edges to internal wall panels are to be finished with approved galvanized steel plaster stops/ Corner beads. Any remaining gap between plaster and concrete, etc. shall be filled with mastic to cover unavoidable cracks between these materials. 1.5.1.8. Cement Wash

The cement wash to fair-faced block work shall be well rubbed or bagged into the surface of the blocks in order to produce an overall smooth surface. 1.5.1.9. External Plastering

All plastering materials shall be measured in a proper gauge box and shall be mixed in a clean container, on a clean board or in an approved machine and all materials shall be used within one hour of the addition of cement; partly set or dried material shall be discarded.



All plastering work shall be protected from direct sunlight and the drying effects of winds during execution and 7 days curing with water. The Contractor shall ensure that all surrounding building work and paving is protected from cement splashes. All water pipes, electrical conduits and other services, soil, waste and anti-syphonage pipes shall be fixed in position, and when necessary securely fixed in chases and recessed, before the execution of any plastering or other similar work. Metal pipe fixings or untreated steel are to be suitably protected from contact with the cement plaster, either by painting with bitumen or by an approved wrapping. The Contractor shall make good at his own expense any cracks, blowholes, or other defects in the cement plastering and the decoration thereafter. The FEWA Engineer may require the whole areas of a wall to be redecorated where such defects occur. New block walls shall be left for minimum 14 days for curing and drying before plastering. Where block walls are to be plastered, joints shall be raked out to a depth of 10mm. All block wall surfaces shall be brushed down with stiff dry brushed to remove efflorescence and loose dirt. A cement/acrylic bonding agent splash coat is to be applied prior to plastering. Low spots and areas shall be dubbed out and sufficient time shall be allowed for the dubbing to dry out before the plastering. Plastering to walls shall consist of two coats of cement and sand mortar to a finished thickness of 20mm. The mix is to be of 1 part Portland cement to 3 parts sand by volume. Sand shall be two parts of black sand and one part of washed white sand. These mix proportions may be adjusted where permitted by the FEWA Engineer to suit the type of block work used. The plastering shall have an appropriate water resistant additive and shall stand firm before being combed or cross-scratched for key. The key coat shall be allowed to dry out thoroughly to allow for complete shrinkage before the application of the setting coat. Rapid drying out shall be avoided by providing shade from direct sunlight, shelter from drying winds and by periodic wetting of the surface for 7 days. Beveled or struck edges shall be worked where the plastering finishes against joinery work, fair-faced concrete, etc., the surface finish shall where adjacent match the existing finishes. Crack inducers or separation membranes shall be provided at centers equal to the height of the wall or as required by the FEWA Engineer. Exposed edges to external panels are to be finished with approved stainless steel plaster stops/ Corner beads. Any remaining gap between plaster and concrete, etc. shall be filled with mastic to cover unavoidable cracks between these materials. 1.5.1.10. Painting of External Surfaces

The external wall surfaces shall be finished with multiplayer polyurethane paint of approved quality and color. The Multi layer polyurethane paint system shall be applied strictly as per the manufacturer’s instruction. The topcoat shall be with two coats of polyurethane paint with texture finish.



The whole painting work shall be carried out by specialist painting applicator with FEWA Engineer’s approval. 1.5.1.11. Roofs

All roofs shall be provided with necessary rainwater outlets to collect storm water and transfer it to the Site surface drainage system. Rain water pipes inside building will not be permitted. Rainwater roof drainage for concrete roofs will be made by UPVC roof outlet connected with 110 mm UPVC pipe from roof to ground level. For truss, rainwater goods shall be constructed from the appropriate grade of Aluminium alloy and color coated with polyurethane topcoat. All gutters shall be laid to falls generally not less than 1: 50. To protect personnel and equipment against excessive heat gains the thermal transmittance (or 'U' value) shall not exceed 0.57 W/m2 °C and the roofs shall be sufficiently dense or otherwise constructed to minimize the effect of solar gain. If a lightweight roof construction is approved this must be securely fixed to resist all forces including upward due to wind. Calculations for the design of fasteners shall be submitted to the FEWA Engineer for approval. 1.5.1.12. Deck Roofs

Metal deck roofs where required shall be PVDF2 coated aluminium decking of approved proprietary manufacture suitable for long maintenance-free life and adequate to withstand the climate and Site pollution conditions. Decking shall be coated both sides of sheets. The decking shall be formed to an approved 'fluted' profile. Samples of the proposed decking shall be submitted to the FEWA Engineer for approval. No orders shall be placed with manufacturers until approval has been given. Flashings shall be formed of the same material as the metal deck units. Externally exposed flashings shall be finished with an approved color. Care shall be taken to prevent bi-metallic corrosion occurring by the use of heavy PVC adhesive tape between the sheeting and the supporting rails, and by the use of fasteners and fixings of suitable materials. The PVC tape shall overlap the edges of the purlins by at least 15 mm along their full length. All fixings shall be stainless steel and designed to withstand the maximum predicted loading with a factor of safety of 2.0. Calculations shall be submitted to the FEWA Engineer for approval. Where metal decking provides the exposed surface the slope of the roof shall not be flatter than 1 in 10.The edges of all sheets, including cut ends, holes, etc., shall be taped, painted or otherwise protected from corrosion to the satisfaction of the FEWA Engineer. All side and end laps of sheets as laid; trimming pieces and flashings shall be sealed with mastic strips or as otherwise recommended by the manufacturer. Where exposed the sheeting shall be similar in all respects to the approved vertical cladding. 1.5.1.13. Roof Finishes

The roof finishes shall consist of 4 mm thick SBS modified bitumen waterproof membrane torch applied over light weight screed with bitumen primer. Waterproofing shall be carried out only by a specialized subcontractor in workmanlike manner and 10 years of warrantee is required for the complete waterproofing system. Waterproofing shall not be allowed to



carry out under weather conditions that may adversely affect the waterproofing system, unless special measures to prevent any possible detrimental effect are taken. Wherever possible all waterproofing materials shall be obtained from one source. Where a different source is used, the manufacturer shall provide compatibility statement for the FEWA Engineer’s approval. Wherever the waterproofing membrane is exposed, this shall be protected with UV resistant mineral skirting. Water proofing for the roof shall be carried our over the lightweight foam concrete screed laid over roof slab in slope. The density of the lightweight screed shall not exceed 800kg/M3. The specialized subcontractor should carry out lightweight screed. Method statement and materials used for this shall be submitted to FEWA Engineer for approval. Samples of lightweight screed shall be taken and has to be weighed to check the density. If the density found to be beyond the limit specified above, then the whole screed has to be removed and replaced with new screed complying with the requirements. Lightweight thermal insulating material of minimum 50 mm thickness and 35kg/M3 density consisting of extruded closed cell polystyrene shall be necessary to provide a 'U' value in accordance with Section B requirements, with geotextile fabric separation. Solar protection shall generally be provided by white color 40 mm thick concrete tiles loosely laid over geotextile member and joints shall be filled with poly-sulphide joint sealant. Up stands and parapets shall be protected with a factory finish ultra violet resistant waterproof membrane. Roof finishes shall conform to the following basic requirements: a) The type of lightweight insulating material, the sheeting adhesives, mastic, and top

dressing shall have the FEWA Engineer's approval. b) The method of laying the finish and the methods of securing the finish at eaves, the

rainwater outlets, shall all be to the satisfaction of the FEWA Engineer. c) The finish shall not allow the passage of water or moisture into the building. d) The structural roof slab (Lightweight screed) shall be laid to a minimum fall 1 mm

per 60 mm run. 1.5.1.14. Concrete Flooring

The concrete flooring shall conform to the following requirements: a) To be wearing, and divided into sufficiently small bays of maximum 2 x 2 meters to

prevent shrinkage cracking. b) To be non-slip. c) To be dust-proofed. d) To be resistant to oil and grease. The type of finish and method of laying shall be to the approval the FEWA Engineer. 1.5.1.15. Preparation of Flooring

The surface of concrete floors to receive concrete screed shall be roughened by removing the latency with stiff boom and stippling immediately after the initial set of concrete. Before laying any flooring or screeding, the surface of the concrete or screed shall be thoroughly cleaned to remove all loose material, dust, oil and grease. Floors shall be thoroughly swept and hosed down with clean water before the screed is laid. Immediately before laying the screed, approved bonding agent shall be applied over the sub-floor. If the surface in not in proper level then required rectification shall be made with the approval of FEWA Engineer.



1.5.1.16. Cement/Sand Screed

Cement/sand screeds are required for all floors where strict adherence to level tolerances for equipment erection is required. Cement screed shall be laid directly on cleaned concrete floor slab in a sound, true and level layer. The surface of the old concrete shall be thoroughly scrabbled to remove all laitance, scrubbed and cleaned to expose the aggregate, thoroughly wetted and then covered with an approved bonding agent well brushed into the roughened surface immediately prior to screeding. At the wall sides and columns, expansion joints shall be provided. Joint filler of bituminous fiberboard 10 mm thick sealed with cold poured, high duty seal shall be used for such joints. The subsequent layer of screed shall not be less than 50 mm thick. Where so directed by the FEWA Engineer, the Contractor shall add approved compounds to the materials before mixing to give a concrete with improved dust-proof and oil-resistant qualities. Such compounds shall be added in accordance with the instructions of the manufacturer. The screed shall be placed in panels not exceeding 9 Sqm. Contraction joints shall be provided around the perimeter of each panel and shall be filled with approved materials. Cement/Sand Screed shall be of grade C40 with 10mm aggregates. It shall be steel floated to a smooth hard finish before final set. The screed shall be kept moist for a minimum of 7 days and shall be protected by approved methods and then allowed to dry. The Contractor shall provide chases, battens, box outs, etc., to support plates and channels, etc., for plant erection. All necessary grooves for door channels, duct channels, etc., shall be provided, and later grouted in. 1.5.1.17. Epoxy Resin Screed

High strength, impact/ abrasion resistant solvent free epoxy resin floor screeds, minimum 6mm thick hall be applied over the concrete screed or over concrete floor. Epoxy screed for the top surfaces of transformer plinths shall be of heavy-duty polyurethane type screed

having softening temperature-exceeding 1000

C. And the thickness of epoxy screed for transformer plinths shall be 10 mm. Whole materials shall be supplied by a manufacturer approved by FEWA Engineer. Epoxy screed for surfaces exposed to direct sun light like platforms, stairs etc. has to be applied with UV resistant special material. Only the specialized applicator shall be allowed to carry out the epoxy screed work. For the transformer plinths, the material manufacturer or their approved applicators only should apply the epoxy screed. The top level of epoxy screed should be perfect and there won’t be any tolerance in level allowed for this work. The whole floor will be subject to rejection if any difference in level found in the epoxy screed. Before application of sealer coat, the contractor has to verify the top level and do the rectification if any required. The screed thickness and laying shall be strictly in accordance with the manufacturer's recommendations and subject to the approval of FEWA Engineer. The concrete floor, which receives the epoxy screed, shall not have moisture content more than 5% and this should be verified and shown to the FEWA engineer before starting any screed work and



has to be recorded. All safety measures recommended by the manufacturer should be strictly followed. All the epoxy screed materials shall be stored in cooled storeroom as per manufacturer’s recommendations. Two coats of epoxy sealer coat shall be applied over the epoxy creed after the initial setting of the epoxy screed and as per manufacturer’s recommendations. Color of sealer coat shall be to the approval of FEWA. Color should be uniform throughout the floor and no variations will be allowed. If any variation found, the whole floor has to be recoated with additional coat to achieve uniform color with no extra cast. 1.5.1.18. Acid/Alkali Resisting Ceramic Tiles Acid/alkali resisting tiles shall be fully vitrified 10 mm thick non-slip type bedded and jointed with acid/alkali resisting epoxy mortar. All top edges and corners, etc., shall be rounded and ordered with the standard tiles. Grout shall be epoxy resin based having acid resistant characters. Tiled up stands shall be provided under all doors at interfaces with non-chemical finished areas. 1.5.1.19. Ceramic Floor & Wall Tiles

Ceramic floor tiles and tiling to BS 6431 and BS 5385 shall be fully vitrified a minimum 10 mm thick non-slip type laid strictly in accordance with manufacturer’s recommendations. In general they shall be provided with coved skirting at all walls and all exposed edges shall be rounded. Bedding mortar shall be cement: sand (1:3) mix. Any admixtures must be approved before use. Grout shall be epoxy resin based. Wall tiles shall be of glazed type and shall be fixed with approved glue over plastered wall. The floor areas shall be divided into bays with approved brass dividing strips. The top of the strips shall be truly level with the finished surface. Tiles shall conform in size, shape, pattern and color with the samples previously submitted to the FEWA Engineer for his approval. Brass dividing strips shall be provided in the floor finishes under all doors.

1.5.1.19.1. Marble Tiles

Marble tiles of 1st quality, even grained and uniform pattern to be obtained from one stratum. Thickness of marble shall be 30mm for floors unless otherwise shown on the drawings. Marble skirting of 100mm wide and 20mm thick to match the marble flooring in the same area. Spread mortar bed 13 to 20mm thick to be used. Mortar shall be 1 to 3 mix of portland cement and sand. White cement to be used for lightly colored marble. Tiles shall conform in size, shape, pattern and color with the samples previously submitted to the FEWA Engineer for his approval. The marble shall be perfectly homogeneous in color, tone and texture. It shall contain no fossil markings, holes, pits or the like. 1.5.1.20. Floor Expansion Joints

Expansion joints are to be formed with an approved preformed movement control joint system satisfactory to accommodate stresses for high transient loading. 1.5.1.21. Stairs, Steps, and Thresholds



Stairs to main doors shall have a hardwearing non-slip epoxy screed finish with skirting. Steps and thresholds for basement and secondary rooms are to be of concrete with corborandam anti-slip surface. Where marble is specified for the stairs, steps, treads & risers to stairs shall be 30 mm thick marble, fixed solid on a bed of white cement/cement and sand (1:3) mix, 25 mm thick (approximately). Skirting shall be marble or 20 mm thick backing on cement and sand to coincide with joints in adjacent paving. Rounded risers, nosing and moulding shall be adequately protected by means of timber casings. Treads and skirting shall be grouted and protected in manner similar to pavings. The treads shall have non-slip corborandam or similar inserts. Thresholds for the buildings shall be of 30 mm thick high quality white marble or aluminium fitter with airtight rubber casket. Threshold for battery room and toilet shall be white marble. 1.5.1.22. Suspended Ceilings

In principle all ceiling panels shall be removable offering to access to the ceiling void for routine inspection and maintenance of services. Where removal of equipment such as valves, dampers, etc., is required lockable-hinged hatchways shall be provided. The proprietary suspended acoustic ceilings shall be fitted flush around light fittings, ventilation ducts, etc., and shall conform to the following requirements: a) Shall be non-combustible. b) Shall not allow the spread of flames. c) Shall be vermin proof. d) Shall easily be cleaned or redecorated. e) Shall be so designed as to allow the easy replacement of panels. f) Shall provide the following minimum sound absorption coefficients:

- 0.47 at 500 Hz - 0.70 at 1000 Hz - 0.90 at 4000 Hz

Samples of ceiling materials including suspension system shall be submitted to FEWA for approval. Shop drawings showing all services, fittings etc., shall be submitted for the approval of FEWA engineer. 1.5.1.23. Concrete Ceilings

Where suspended ceilings are not required, rooms shall have decorated fair-faced concrete ceilings free from board marks and finished with "V" joints in a regular pattern over the soffit. They shall be painted or decorated as specified. 1.5.1.24. Plumbing

All water supply pipes and waste pipes are to be of appropriate grade of UPVC or G.I., complete with appropriate fittings. All hot water pipes shall be of copper. Pipes and fittings laid below ground level shall be of the correct grade for this purpose. Workshops and chemical areas are to have taps with hose connections. Acid/ Alkali resistant waste pipes are to be provided for battery rooms.



Plumbing shall generally be surface mounted and enclosed by easily removable, re-usable proprietary factory manufactured products. 1.5.1.25. Sanitary Fittings

Sanitary fittings shall be of white glazed fireclay. The articles shall be glazed inside and outside and fixed with stainless steel screws and decorative caps. Battery rooms are to be provided with a suitable eye bath and wash basins with alkali resisting fittings and long handle 'bib' taps. All fittings and installations are to be approved by the FEWA Engineer. 1.5.1.26. Metalwork Generally

All metalwork shall be designed, fabricated and fixed to the satisfaction of the FEWA Engineer and shall comply with this Specification. 1.5.1.27. Windows

The window frames are to be of anodized aluminium alloy with polyurethane powder coated color coat finish supplied complete with hinges and pivot pins, fixing lugs, handles, and stays, glazing clips, etc., all of non-corrodible materials. Opening windows shall be provided with insect screens comprising aluminium frames with Nylon or other corrosion resistant material screens. Windows shall be designed and constructed to enable cleaning and glass replacement to be carried out from inside. Windows to air-conditioned rooms shall be of a non-opening type but with facilities for removal from the inside for cleaning and maintenance. Sun shields shall be provided over and to the sides of window frames. Double glazed windows shall be 8 mm thickness and shall be to the approval of the FEWA Engineer. Aluminium windows shall be framed in extruded aluminium bars and glazing sections. The aluminium shall be of a type comparable to the appropriate National Standard described as a heat-treated material in the solution-treated and naturally aged condition and as a material in the air quenched and precipitation treated conditions to the following percentage composition: Cu 0.1 Mg 0.4 -0.9 Si 0.3 -0.7 Fe 0.5 Mn 0.3 Ni None Zn 0.1 Cr 0.1 Ti 0.2 Remainder Aluminium Where window controls are positioned above a height of 1800mm from floor level, then these windows are to be provided with rod and lever or enclosed cable-operating gear. The windows are to be glazed with glass of an appropriate thickness to suit the opening.



Generally polished plate glass will be needed, sometime wired, but also roughcast glass may be used in certain cases. Tinted or solar reflective glass shall be used. The whole design and detailing of the windows is to be to the approval of the FEWA Engineer. 1.5.1.28. Doors and Frames All doors for equipment room shall be fire rated steel doors manufactured by a specialist manufacturer to the approval of the FEWA Engineer. All doors except folding shutter type over 2200 mm high shall be provided with removable transoms. All steel doors shall be minimum 2-hours fire resistant. All doors, frames and accessories shall bear the identifying label of the testing laboratory. All iron mongeries shall be stainless steel of minimum grade SS 316 first quality form reputed manufacturers. All Ironmongories shall bear the name and product code. The contractor may submit a written certificate from a nationally recognized testing agency and from local civil defence for fire rating confirmation. Installation, hardware and operational characteristics shall conform to NFPA standards No. 80 & 80A and NFPA code for safety to life No.101. The thickness of metal used for door frames shall not be less than 2 mm and the metal thickness of door shutter shall not be less than 1.6 mm. Frames shall be provided with minimum of tree wall anchors. Doors shall be 50 mm thick, and door clearances shall not exceed 3 mm at head and jambs, 10 mm at bottom from finished floor level and 6 mm at meeting stiles of pair of doors and shall be provided with astragal to seal the gap. Marble threshold of minimum 30 mm thick shall be provided for all external doors, toilet doors and for battery room doors. All the doors shall be with edges welded and finished flush. Seems and joints are not acceptable on door faces or edges. Reinforce outer face sheets with minimum 1.6 mm interlocking vertical channels or Z shaped members spaced not over 150 mm apart and spot welded to outer face sheets. Provide continuous reinforcing channels welded to face sheets at top and bottom of door. Place full thick cork, fiber board or mineral wool board in spaces between reinforcing channels. Additional stiffeners shall be provided wherever ironmongeries are to be fixed. A company specializing only in door manufacturing and having a minimum of 20 years worldwide experience shall manufacture all doors, frames, and ironmongery. Where air locks are required they shall be provided with two sets of double doors with removable transoms of sufficient size to suit all plant access and removal. All doors shall be complete with all necessary and appropriate fixing lugs, hinges, threshold strips, vision panels of polished wire-glass, hard wearing ironmongery, kick plates, push plates, automatic closures with hold-open facility, locks and all exit doors and passage doors provided with panic bars and panic bolts. All external doors and frames shall be fitted with approved weather seals. For external doors, automatic closures are to be fitted internally. Steel door frame shall have a grove on hinge sides to arrest hot air and dust entry. Galvanized steel doors and frames are to be powder coated or painted in accordance with the steelwork painting specification or as instructed by FEWA. Topcoat shall be polyurethane.



Only the manufacturer/ supplier shall do the installation of doors. Rooms containing equipment liable to risk of fire or explosion shall have at least two doors located on opposite walls, the doors must open outwards and be fitted with panic bars and bolts and be fire resistant. The whole design and detailing of the doors shall be to the satisfaction of the FEWA Engineer. Intumescent fire seals are to be inserted into grooves in the edges of all fire resistant doors. Shop drawings including door schedule shall be submitted for approval and they indicate the following information. Location of each door and frame. Elevation of each type of door and frame. Details of construction. Method of assembling sections. Gages of metals. Location and extend of hardware reinforcement. Location of hardware. Type and location of struts and anchors for frames. Identification of surface preparation, pre treatment and shop primer. Finish detail. All internal doors shall have viewing glass panels. All glass shall comply with an appropriate approved National Standard. All doors shall have stainless steel name plates with room names engraved on it. The text shall be both in Arabic & English and shall be UV resistant. Name plate for the substation main gate shall be stainless steel with letters in colour engraved on the plate. FEWA logo in colour shall be engraved on the plate. All name plates shall be fixed only by invisible screws, adhesives will not be permitted. Where required all flush timber doors shall be solid cored and shall be covered on both sides with external quality plywood finished ready for painting. The doors shall be lipped and edged with hardwood strips. 1.5.1.29. Locks and Door Furniture

Samples of all door furniture, which is to be of a very high quality and heavy duty, are to be submitted to the FEWA Engineer for his approval. All locks shall be provided with three keys, which on completion of the work shall be clearly and securely labeled in suitable cabinets. All locks are to be mastered to existing systems and master keys provided. All locks shall be provided with 3 keys, which upon completion of the works, shall be clearly and securely labeled in 3 sets of suitable cabinets. The number and size of cabinets to be provided will be subject to the approval of the FEWA Engineer. 1.5.1.30. Timber

Timber and other hardwood materials used for the permanent works shall be straight, kiln dried sound, bright, matured, well seasoned, and conditioned to suite the particular purpose for which it is to be used. The material shall be free from warp, sapwood, signs of rot, shakes, large and loose knots, worm holes, wanes, cracks and other defects and shall



be sawn or wrought die square and true on all four sides. Timber shall conform to the appropriate National Standard approved by the FEWA Engineer. Timber for concealed work shall be an approved hardwood. All timber for exposed joinery shall be approved selected Iroko or approved equivalent. Such timber may contain sound or tight knots on any surface if the mean diameter of any one-knot does not exceed 20 mm and the knot nowhere occupies more than one sixth of the width of the surface. The FEWA Engineer will have the right to reject any timber not confirming to the "selected" standard. Where timberwork is required wrought it shall be supplied machine dressed. All joints, mortises, tendons, housings, and the like shall be perfectly formed and fitted. All faces of timber in direct contact with block work, concrete or rendering shall be protected with approved primer before fixing. All timber incorporated in the permanent works is to be pressure impregnated to give full protection from insect and fungal attack. The treatment is to include protection against termites. The type of preservative used and method of treatment are to be to the approval of the FEWA Engineer. All timber shall be well seasoned with minimum appropriate moisture content. The moisture content of timber shall be 8 to 12% for interior finish components and 10 to 15% for structural parts in permanent connection with the outside air. The Contractor shall provide and maintain all temporary covering, and shall box-in and protect all work liable to damage. 1.5.1.31. Painting of Woodwork and Timber Where possible the moisture content of joinery timber at the time of painting should not be more than 15%. All wrought woodwork shall be prepared and primed in the joiner's shop. Large resinous knots and pitch pockets shall be cut out and replaced by sound wood. Small knots and pitch streaks shall then be given two coats of patent knotting. As soon as the knotting is thoroughly dry the whole of the joinery shall be given a coat of priming paint, care being taken to work the primer into all quirks, crevices and nail holes. End grain shall be given two coats of primer. Spraying will not be permitted. All joints shall be thoroughly primed before assembly. After erection on Site any primer, which has been damaged in any way, shall be touched up or re-coated. Any part of the work in contact with block work, window frames, etc., or otherwise covered up, shall be given an additional coat of aluminium wood primer. The priming paint for woodwork intended for external work and for internal windowsills, frames, ledges, sashes, etc., shall be good quality white lead linseed oil primer containing about 10% red lead. For general interior work a leadless linseed oil gray primer shall be used. Hardwood joinery, which is to be painted, shall be primed with aluminium wood primer, hardwood, or teak priming varnish. The backs of hardwood joinery not painted on exposed faces shall be similarly treated. When the primer is dry, and before applying the undercoats, all cracks, nail holes, etc., shall be stopped with a suitable, stopper. Woodwork, which has been primed for some time shall be wiped down and rubbed with damp abrasive, leathered off and allowed to dry



before applying the undercoats. The joinery shall then be given two coats of the undercoating paint recommended and supplied by the manufacturer of the finishing paint. All exterior and interior woodwork shall be given one topcoat of alkyd resin enamel paint. All structural timber that does not require to be painted, e.g., timber joints, flooring, staircases and the like, shall be treated with two coats exterior grade approved timber preservative. 1.5.1.32. Oiling Hardwood

Hardwood described, as being oiled in indoor locations shall be treated with two coats of raw linseed oil. Hardwood described as being twice oiled and varnished shall be treated with two coats of raw linseed oil followed by one coat of clear marine varnish. 1.5.1.33. Wood Screws

Wood screws shall be of brass conforming to approve National Standards. Where aluminium components are fixed to joinery work, aluminium screws and washers shall be used. 1.5.1.34. Hand railing and Balustrades

Architecturally designed ornamental steel hand railing and balustrades shall be provided for the offloading platforms and wherever required. The balustrades shall be of high quality and samples shall be submitted to the FEWA Engineer for approval, together with drawings. All handrails shall be galvanized and painted with epoxy paint system as per FEWA Engineer’s approval. Handrails shall be made of steel pipe of minimum 50 mm diameter (O.D) with flush, continuous welded joints ground smooth. Handrails shall be of minimum 1.2 m high from the finished floor level. All handrails for offloading platforms shall be of removable type. 1.5.1.35. Access Ladders

The contractor shall provide all ladders to heights and access as required to climb on top of all roofs and cable basements. All ladders exceeding 2 m heights shall be secured with safety cages. Cage vertical and horizontal spacers shall be arranged such that man cannot fall in the gap. Maximum of 300 mm space will be allowed. All ladders shall be fabricated with mild steel and has to galvanized after fabrication and painted with epoxy paint in required color as per FEWA Engineer’s approval. Side rails shall consist of 75x12 mm flat, or “L” angle of size 75x75x10 mm according to unsupported lengths and 25mm diameter pipe rungs welded to the side rails. Rungs shall be 500mm long between side rails and spaced 300mm centers. The ladders shall be secured to steel work or reinforced concrete work in the main structure or as approved by the FEWA Engineer, and the foot of each ladder will normally be required to bed properly on a prepared foundation unless the wall fixing brackets are designed to cater for all possible loading.



1.6. PIPE, DRAINAGE AND CABLE DUCTS



TABLE OF CONTENTS

Page 1.6. PIPE, DRAINAGE AND CABLE DUCTS.............................................................. 106

1.6.1. Trench Excavation................................................................................................ 106

1.6.2. Trenches under Roads......................................................................................... 106

1.6.3. Pipe work .............................................................................................................. 107

1.6.4. Steel Pipes (Associated with Civil Works) ........................................................... 107

1.6.5. Concrete Pipes..................................................................................................... 108

1.6.6. Pitch Impregnated Fiber Pipes ............................................................................. 108

1.6.7. Vitrified Clay Pipes................................................................................................ 108

1.6.8. Glass Reinforced Plastic Pipes............................................................................ 108

1.6.9. Fiber Cement Pipes.............................................................................................. 108

1.6.10. PVC Pipes ............................................................................................................ 109

1.6.11. Acid/Alkali Resisting Drain.................................................................................... 109

1.6.12. Testing .................................................................................................................. 109

1.6.13. Sterilization of Installation ..................................................................................... 109

1.6.14. Soak ways ............................................................................................................ 109

1.6.15. Laying and Jointing Pipes - General ..................................................................... 109

1.6.16. Bedding and Surrounding Pipes........................................................................... 109

1.6.17. Backfilling.............................................................................................................. 110

1.6.18. Manholes Gullies and Valve Pits........................................................................... 110

1.6.19. Covers, Gully Gratings and Frames..................................................................... 110

1.6.20. Step-Irons ............................................................................................................. 110

1.6.21. Rodding Drainage Pipelines ................................................................................. 111

1.6.22. Excavation for Cable Ducting on Land ................................................................. 111

1.6.23. Preparation of Trench Bottom to Receive Ducts on Land ................................... 111

1.6.24. Sand as Bed and Surround to Ducts ................................................................... 111

1.6.25. Linearity................................................................................................................. 111

1.6.26. Laying of Ducts..................................................................................................... 111

1.6.27. Multiple Runs of Ducts.......................................................................................... 111

1.6.28. Cutting of Ducts.................................................................................................... 111

1.6.29. Bell mouths........................................................................................................... 112

1.6.30. Cleaning and Testing of Ducts ............................................................................. 112



1.6.31. Draw Wires........................................................................................................... 112

1.6.32. Sealing of Electrical Ducts and Openings............................................................ 112

1.6.33. External Concrete Cable and Pipe Trenches....................................................... 112

1.6.34. Drainage Sumps................................................................................................... 113

1.6.35. Excavation for Cables........................................................................................... 113

1.6.36. Site Services – General........................................................................................ 113



1.6. PIPE, DRAINAGE AND CABLE DUCTS 1.6.1. TRENCH EXCAVATION Trenches shall be excavated to the required lines, levels and sizes that will allow for the pipe wall thickness and bedding thickness, and to widths that will allow proper and efficient jointing to be carried out in clean and dry conditions. Trench bottoms shall be compacted by ramming before any pipes are laid. At all times a minimum cover of 1000mm shall be maintained over pipes except under roads or hard standings where the cover shall be 1 m unless the pipes are protected by concrete where the cover may be reduced. PVC pipes shall not be encased in concrete but have a relieving concrete slab over. The trench excavation and filling shall be so executed that all walls, roads, sewers, drains, pipes, cables, structures, places and things shall be reasonably secured against risk of subsidence or injury and shall be carried out to the satisfaction of the authorities concerned. Where trenches pass from a footway to a roadway or at other positions where a change of level is necessary, the bottom of the trench shall rise or fall gradually. The rate of rise of fall shall be approved. Unless otherwise agreed, provisions shall be made during excavation and until restoration has been completed, for reasonable access of persons and vehicles to property or places adjacent to the route. Excavated Material The materials excavated from each trench shall be placed so as to prevent nuisance or damage to adjacent ditches, drains, fences, gateways and other property or things. Excavated materials shall be stacked so as to avoid undue interference with traffic. Where, owing to traffic or for reasons of safety or other considerations, this is not permissible, the excavated materials shall be removed from the site and returned for refilling the trench on completion of laying. Surplus material shall be disposed off by and at the cost of the Contractor. Timber Left and Built In Where required for the security of the Works or adjacent buildings or structures, timber installed for the support of trenches, joint bays, headings, tunnels, etc., shall not be withdrawn but shall be left in position. 1.6.2. TRENCHES UNDER ROADS All trenches for cables, services, drains and the like in or adjacent to the roads or surfaced areas shall be completed, backfilled and compacted before the subbase is laid. The Contractor shall satisfy the FEWA Engineer as to the proper consolidation of all backfilling in trenches. Any subsidence shall be made good and tested to the FEWA Engineer's satisfaction. Damage to the road or surface area foundation or surface due to subsidence



of trench filling shall be made good at the Contractor's expense. The material employed shall be non-plastic and to the FEWA Engineer's satisfaction. All services shall be laid inside ducts that are surrounded by 300 mm of concrete on all sides. The bottoms of all trenches shall be trimmed to grade and level and thoroughly consolidated by ramming before any bedding is placed or pipes laid. Material less than 300 mm above the top of the pipes shall be thoroughly compacted in layers of selected fine material not exceeding 150 mm using hand rammers. Where in the opinion of the FEWA Engineer backfilling is unsatisfactory, it shall be removed and replaced in accordance with the Specification. The requirements of this clause shall apply outside the road pavement for a distance of 2.5 m from each kerb line. 1.6.3. PIPE WORK The Contractor shall construct pipelines, drains, and the like to the lines and levels required. He shall provide the materials in accordance with the specification given below. The types of pipes proposed for each drainage system shall be submitted for FEWA Engineer’s approval. All pipe work shall be installed strictly in accordance with the manufacturer's instruction. For pipe protection painting and identification standard practice shall be followed as per FEWA engineer’s instruction. Pipe work passing through floor slabs and firewalls shall have an approved proprietary fire protection 'collar' fitted. 1.6.4. STEEL PIPES (ASSOCIATED WITH CIVIL WORKS) Steel pipes shall comply with an appropriate National Standard approved by the FEWA Engineer. Pipes shall be welded or lap-welded as specified. Welded pipes shall be made from not more than two plates with two longitudinal welds and no circumferential welds will be permitted except for large diameter pipes, built-up bends and flanges. Each pipe barrel when welded up shall be truly cylindrical and circular in cross section and shall comply with the tolerances laid down in the Standards mentioned above. Unless directed otherwise, internal coatings and linings for steel and cast iron pipes and specials shall comply in all respects with the requirements of the appropriate National Standard. Mild steel pipes, bends and Tees manufactured for installation in the drinking water main shall generally be flanged except where jointed to fiber cement pipes when the ends shall be built up as necessary for use with 'Reka' pressure couplings. The lining of the pipe work shall be in every way suitable for carrying potable water. Steel pipes shall be coated with Epoxy fusion bonded by immersion in fluidized bed of Epoxy powder and wrapped according to the requirements of Book II. The Contractor shall protect coatings, coverings, and linings during and after erection to minimize such damage from whatever cause.



1.6.5. CONCRETE PIPES Concrete pipes are to be made by an approved manufacturer using sulphate-resisting cement. The pipes and specials shall comply with BS 5911. High alumina cement shall not be used in the manufacture of the concrete pipes. The ends of concrete pipes shall be truly square to the centerline. Any bituminous painting, which may be specified, shall be kept from contaminating the contact surfaces of rubber rings where these are used. If the pipes are due to be rigidly jointed they shall be laid on the sound undisturbed bottom of a trench on rigid pedestals or on a continuous bed of concrete with suitable depressions prepared for the joints, according to the design. Unless otherwise specified, the joints shall be made with 2:1 sand-cement mortar. Whether it is a spigot and socket joint or an ogee joint, the mortar shall be packed from outside against a seal of tarred rope or yarn, and the inside of the pipe shall be left clean of mortar; in large pipes the inside of the joint shall be pointed flush. The ends of the pipes shall be wetted before the mortar is packed into the joint. Concrete pipes due to be flexibly jointed shall, unless otherwise specified, be firmly laid on a bed of compacted granular spoil which shall be free from all stones larger than 25 mm and in which depressions shall be hollowed out to receive the sockets and allow the proper execution of the joints, unless some other patent joint is specified or permitted. The joint shall be made with rubber rings to produce a watertight joint. 1.6.6. PITCH IMPREGNATED FIBER PIPES Pitch fiber pipes used in the works are to comply with and are to be laid in accordance with the requirements of BS 2760 and they shall be obtained from approved manufacturers. 1.6.7. VITRIFIED CLAY PIPES Vitrified clay pipes shall comply with BS 1143. The glazing on the pipes is to be either glass or ceramic and not a salt glaze. The type of joint used on the pipes is to suit the effluent being carried and is to be to the FEWA Engineer's approval. Particular attention is to be paid to the packing, handling and transportation of clay pipes to avoid damage. 1.6.8. GLASS REINFORCED PLASTIC PIPES Glass reinforced plastic pipes shall comply with AWWA C950 for below ground potable water and drainage and ASME code of practice 1792 for above ground pipes. Fire mains shall be glass-reinforced epoxy to the appropriate NFPA requirements. 1.6.9. FIBER CEMENT PIPES Fiber cement pipes shall comply with BS 3656. Where the use of rubber rings is ordered or approved for jointing they shall also comply with the requirements of BS 2494. Pipes shall be jointed in accordance with the manufacturer's instructions. These pipes may only be used with the express permission of the FEWA Engineer in writing.



1.6.10. PVC PIPES PVC pipes shall confirm with BS 3506 and shall be laid and jointed in accordance with the manufacturer's instructions. Other types of pipelines, where ordered by the FEWA Engineer, shall be laid and jointed in accordance with the manufacturer's instructions. 1.6.11. ACID/ALKALI RESISTING DRAIN Drainage from battery rooms, chemical areas and boilers shall be led to neutralization pits by means of approved acid resisting pipe work. Jointing materials appropriate to the various effluents in the pipes must be used. All manholes and structures leading to the neutralization pits shall be coated with acid/alkali resistant epoxy mortar lining (minimum 5 mm thick). 1.6.12. TESTING All water mains shall be pressure tested to 1.5 times the working pressure; all foul drains shall be tested for water tightness in accordance with BS CP 301. The Contractor shall provide all equipment, anchors and the like necessary for testing and shall carry out all tests to the satisfaction of the FEWA Engineer. 1.6.13. STERILIZATION OF INSTALLATION All mains and services to be used for potable water shall be sterilized before being brought into use, in accordance with the appropriate National Code of Practice approved by the FEWA Engineer. 1.6.14. SOAK WAYS Properly designed soak ways will be provided with a cover slab of concrete of manhole 1.6.15. LAYING AND JOINTING PIPES - GENERAL All pipe systems shall be laid to true and even falls and to the lines and levels required. The Contractor shall supply and fix in all pipe runs, all necessary bends, tees, tapers, valves, hydrants and other specials and shall carry out all necessary cutting, coring, drilling holes, jointing and connecting to new and existing work. All joints shall be made in accordance with the manufacturer's instructions and recommendations, and with BS CP 301 and CP 310. Surplus joint material shall be removed from inside and outside pipes where necessary. 1.6.16. BEDDING AND SURROUNDING PIPES Pipes generally, unless bedded on concrete, shall be bedded on a layer or sand 100 mm thick under the barrel of the pipe. Where indicated or ordered, pipes shall be bedded and surrounded with concrete 150 mm thick. Concrete surrounds in the vicinity of joints shall not be placed until the pipes have been tested and approved by the FEWA Engineer. Pipe laying shall not commence until the prepared trench has been approved by the FEWA Engineer.



1.6.17. BACKFILLING Backfilling shall not be commenced until the FEWA Engineer has approved the complete length of pipe laid. Where pipes are not surrounded by concrete, they shall be backfilled with approved sand to a thickness of 100 mm over the pipe barrel and then with approved material, which shall exclude sharp or excessively heavy material. Backfill to pipes that are surrounded by concrete shall be of approved material devoid of heavy stones. All backfill shall be thoroughly compacted in layers not exceeding 150 mm thick to a density appropriate to the material through which the pipeline runs, and all surplus excavated material shall be disposed of as directed. Any warning tapes or markers required shall be provided in the required position at required depth. 1.6.18. MANHOLES GULLIES AND VALVE PITS Manholes shall be provided at every change of alignment or gradient at the head of all sewers or branches at every junction of two or more sewers and wherever there is a change, in size of sewer. Manholes and inspection chamber shall be constructed of approved precast concrete sections in accordance with BS 5911 or of concrete cast insitu. Foundations shall be of concrete; the channels being finished smooth in concrete, or by using performed half circle channels, haunched up to the manhole sides in neat cement. All manholes and inspection chambers shall be watertight on completion. Frames for manhole covers shall be set in cement mortar. For depths greater than 1 m, step irons as specified shall be provided, spaced 300 mm alternatively vertically and 250 mm horizontally. Gullies shall be approved precast units of concrete in accordance with BS 5911 with gratings and frames. Precast manholes and gullies shall be surrounded with at least 150 mm of concrete brought up to the underside of the frames. Surface water road drainage manholes shall be identical to the existing manholes. Valve pits shall be suitably sized to allow removal of valves without the use of special tools. Chemical gullies, pits and manholes from battery rooms and chemical areas are to be coated internally with an approved epoxy resin liner of 5 mm minimum thickness. 1.6.19. COVERS, GULLY GRATINGS AND FRAMES All covers, gratings and frames shall be of Ductile Iron to BS 2789 heavy duty, Grade A to BS 497. Covers shall all be double sealed and sewage manholes shall additionally incorporate an internal GRP cover seal. FEWA Logo should be engraved in the top of covers. Road drainage manholes shall incorporate GRP covers identical to the existing covers. 1.6.20. STEP-IRONS Step-irons shall be galvanized and painted complying with BS 1247 shall be built into walls of manholes, chambers and pits in a manner approved by the FEWA Engineer. In insitu concrete works the step-irons shall be built in as the work proceeds. In the case of manholes constructed with precast concrete rings step-irons shall be inserted into the rings by the Manufacturer and shall be positioned as required.



1.6.21. RODDING DRAINAGE PIPELINES Provision is to be made for rodding all pipelines. For this purpose manholes for buried pipelines shall be not greater than 25 m apart. Pipelines above grounds level shall have access plates on each bend or junction. All rainwater down pipes shall have an access plate 750 mm above ground level. 1.6.22. EXCAVATION FOR CABLE DUCTING ON LAND The bottom of every trench shall be carefully leveled and rammed. Where it is necessary to change level, the bottom of the trench shall rise or fall gradually as the FEWA Engineer may direct, but in no case at a slope greater than that given by the specified permissible deflections at joints. A minimum cover of 1 meter shall be provided. 1.6.23. PREPARATION OF TRENCH BOTTOM TO RECEIVE DUCTS ON LAND Except where ducts are to be encased in concrete, pockets shall be taken out of the bottom of a trench at all points where joints occur so that the barrels of the ducts rest on solid ground. Plain-barreled pipes are to be bedded to the FEWA Engineer's approval. 1.6.24. SAND AS BED AND SURROUND TO DUCTS Except where ducts are to be encased in concrete, sand is to be packed and well tamped round the duct until it is covered to a depth of 750 mm above the upper surface of the duct. Filling above this level is to be approved excavated material free from large stones. In multiple duct runs the interstices between the ducts are to be filled with sand and compacted and the cover of 750 mm is to be above the uppermost ducts. The sand used shall be the same quality as approved for use in making concrete. 1.6.25. LINEARITY The line of cable ducts shall be kept as straight as possible. Where it becomes necessary to deflect ducts from a straight line or vary the depth, large radius bends may be used subject to the FEWA Engineer's approval. 1.6.26. LAYING OF DUCTS Telephone and electrical cable ducts shall be laid and jointed in accordance with the manufacturer's instructions or FEWA Engineer’s instruction. 1.6.27. MULTIPLE RUNS OF DUCTS Electrical cable ducts in multiple runs whether encased in concrete or not, shall be laid at approved centers vertically and/or horizontally. The minimum concrete encasement where required is to be 150 mm. The final jointing of ducts in multiple runs shall be done in the trench, i.e., the duct shall be lowered and jointed singly and not in groups, and duct joints shall be staggered by approximately half the duct length in alternate lines. 1.6.28. CUTTING OF DUCTS The Contractor shall do any necessary cutting of the pipe ducts according to the requirements of the work. Except where ducts enter the cable through at an angle, they shall be cut at right angles to the length of the ducts. The inside edges of cut ducts shall be



thoroughly rounded off or so dressed before being placed in position that there can be no possibility of damage to cables from the edges of the ducts. 1.6.29. BELL MOUTHS All electrical ducts entering draw pits, buildings and basements shall be provided with approved bell mouths. Bell mouths shall be with puddle flange in the center portion with corborandam finish to have mechanical bond with concrete. 1.6.30. CLEANING AND TESTING OF DUCTS On completion of all electrical cable ducting, two mops of appropriate size connected one to each end of an iron mandrel shall be passed twice through each way to clean the conduit and to remove any foreign matter which may have entered. All proving tests shall be carried out in the presence of the FEWA Engineer and if any obstruction or other defect be discovered it shall be removed or rectified forthwith to his satisfaction. 1.6.31. DRAW WIRES Each electrical duct whose length exceeds 3 m shall be provided artificial fiber cord. The length of draw-wire installed shall be such that 1 m of draw-wire extends from each end of each duct. After the ends of ducts have been sealed the free ends of the draw-wires shall be neatly coiled or otherwise stowed as directed by the FEWA Engineer. 1.6.32. SEALING OF ELECTRICAL DUCTS AND OPENINGS The Contractor shall provide fire protection to all cable ducts, holes, openings and shafts through concrete and block work walls, floor slabs, etc., as follows: a) Ducts through basement walls are to be sealed after cables are laid with suitable

expanding grout to the approval of the Fire Officer. b) Holes through floor slabs are to be sealed after cables are laid with soft fill of

suitable fire resistant material or equal approved. c) Holes for future cable through floor slabs are to be sealed with concrete. d) Horizontal tunnels are to be sealed with block work walls and fire resistant door or

panel to the approval of the FEWA Engineer. e) Vertical shafts are to be sealed with fire resistant paneling fitted around cables

together with soft fill of suitable fire resistant material as previously referred to. f) Intumescent sealant shall be applied to the joints around pipes, cables, etc. and

block work/concrete. 1.6.33. EXTERNAL CONCRETE CABLE AND PIPE TRENCHES In-situ concrete trenches, as approved by the FEWA Engineer, are to be provided inside and outside the buildings. The trenches are to have falls in the floor and must be drained at regular intervals. All trenches must have trench covers suitable for their location and loading. Any beams supporting covers must be as shallow as possible to avoid interfering with the pipes and cables in the trench. Once the trench covers have been made they are to be stored and not laid until all trench cabling, piping, etc., is completed. Any covers laid before this time which become damaged must be replaced at the Contractor's expense. Trench covers shall be of light duty except for heavy traffic areas where heavy-duty covers required. In areas subject to aggressive liquid, GRP covers and gratings shall be provided. Where trench covers and



removable beams are reinforced, they shall be suitably marked to indicate the bottom face and provided with proprietary threaded lifting bolts, filled with grease and capped. 1.6.34. DRAINAGE SUMPS All trenches within buildings shall be provided with drainage sumps connected into the main drainage system and pumps (4 no. Total) to enable fire-fighting water to be drained off. 1.6.35. EXCAVATION FOR CABLES Cables are to be laid in lines and levels as approved by the FEWA Engineer. Their depth below ground level will depend upon the voltage associated with the cables but in all cases the excavation must provide a clear trench. Sand filling below, around and above the cables will always be required and protection covers or tiles will be placed in position over the sand filling before final backfilling to the ground level. The line of the cable trenches shall be marked with suitable posts. 1.6.36. SITE SERVICES – GENERAL Services, manholes etc.; shall not be located within 20 meters of areas designated for future buildings or services.



1.7. RAISED MODULAR FLOORING



TABLE OF CONTENTS

Page 1.7. RAISED MODULAR FLOORING.......................................................................... 116

1.7.1. Scope.................................................................................................................... 116

1.7.2. Related Documents.............................................................................................. 116

1.7.3. Contractor's Responsibilities................................................................................ 116

1.7.3.1. Accessories..........................................................................................................116

1.7.4. General ................................................................................................................. 117

1.7.5. Design Data.......................................................................................................... 117

1.7.5.1. General .................................................................................................................117

1.7.5.2. Floor Loading - Normal .........................................................................................117

1.7.5.3. Floor Loading - Above Normal ..............................................................................117

1.7.5.4. Tolerances............................................................................................................118

1.7.6. Design Conditions ................................................................................................ 118

1.7.7. Materials................................................................................................................ 118

1.7.8. Fabrication ............................................................................................................ 118

1.7.8.1. Floor Panel or Tray ...............................................................................................118

1.7.8.2. Floor Panel Covering ............................................................................................118

1.7.8.3. Floor Panel Soffit Treatment.................................................................................118

1.7.8.4. Electrical Earthing.................................................................................................118

1.7.9. Inspection Requirements...................................................................................... 118

1.7.10. Testing .................................................................................................................. 119

1.7.11. Protection of Metal Surfaces ................................................................................ 119

1.7.12. Preparation for Shipment...................................................................................... 119

1.7.13. Storage Requirements ......................................................................................... 119

1.7.14. Installation of the Floor.......................................................................................... 119



1.7. RAISED MODULAR FLOORING 1.7.1. SCOPE This specification describes the minimum requirements for the design, selection, manufacture and erection of a Raised Modular Floor where it is required to gain access to the cable void beneath the floor. The choice of type of floor will be dependent upon the need for total or partial clear access, and the static or moving loads imposed upon the floor. 1.7.2. RELATED DOCUMENTS BS 476 Part 7: 1971 : Fire tests on building materials structures. Surface spread of flame test for materials. Building Regulations 1985 : To include all latest amendments. BS 2989 : 1982 : Galvanized and Zinc Alloy Coatings. BS 5588 : Part 3 : 1983 : Fire Resistance in Buildings. BS 6266 : 1982 BSCP : Fire Protection for Electronic Data Installations Processing 1.7.3. CONTRACTOR'S RESPONSIBILITIES

The Contractor shall provide all necessary test data and certification to substantiate his material/design on load bearing, fire and anti-static classifications. The Contractor shall provide a full set of detail construction drawings for all floors within the contract. Detailed Drawings shall be submitted to FEWA for approval prior to fabrication and/or construction taking place. The Contractor shall ensure that all his drawings have been fully checked prior to submission for approval. The Contractor shall include for the supply and delivery to site of the complete floor system suitably packed/crated, and installation by skilled team of craftsmen. 1.7.3.1. Accessories The Contractor shall provide as part of his supply the following: Cutting and forming openings within the floor and supply of proprietary edging strips and PVC seals. Supply and fixing of standard, adjustable air grilles to a specified manufacture. Four (4 nos.) lifting devices to enable the floor panels to be lifted. These have to be handed over to FEWA upon project completion or building completion whichever is the sooner. Spare panels will be dependent upon either the number of individual area or the total floor area. The number of panels will be specified on the enquiry documents, but in general the number of spare panels will be not less than five (5) percent minimum. All spare panels shall be complete with the floor finish applied and ready for installation when required. Ramps, stairs, handrails etc., shall be included.



1.7.4. GENERAL The floor shall consist of 600 x 600 mm removable floor panels supported on a removable stringer floor system. This shall consist of floor panels supported continuously on all four edges on easily removable snap-on metal stringers supported on steel adjustable pedestals or supports. The selection of the type of floor will be dependent upon a variety of criteria and the following should be considered in making a final selection but not necessarily limited to these: Height of floor void to concrete base Heavy equipment point loads Heavy moving loads Freedom of access to cable void The floor panels shall be installed in such a manner that any one panel can be easily removed for access to the cable void below the floor. When any one or all such panels are removed, the floor shall remain as a rigid assembly without the need for temporary restraints. The panels shall be edged with rigid PVC lipping on all edges to provide a seal for air conditioning and fire protection gas discharge below the floor. The floor finish to the panels will depend upon client selection but generally a preference will be given to an anti-static, hard print laminate to a core material of high density processed timber (chipboard) or WBP plywood, seated in a 0.9 mm galvanized steel tray with vertical side returns, sealed to the floor covering. 1.7.5. DESIGN DATA 1.7.5.1. General Due to minor design variations and materials of manufacture, floor loading capacity in terms of point loading and uniformly distributed loads may vary slightly between different vendors. However, the following conditions shall provide a broad basis for selection and the Contractor shall indicate where his design differs from those stated. 1.7.5.2. Floor Loading - Normal

Each panel shall be capable of supporting a point load of 5 kN on a 25 mm square anywhere on the panel surface, with the deflection produced not exceeding 2.0 mm when measured from immediately below the load area. The complete flooring installation shall be capable of supporting a uniformly distributed load (UDL) of 24kN/m2 with a maximum deflection produced not exceeding 2.0 mm. 1.7.5.3. Floor Loading - Above Normal For loads greater than those described above one of the following alternatives shall be considered: Provide a separate structure under the equipment to totally relieve the floor panels of high point loads. Provide special 'Shock Load' support props, which will increase the loading capacity of the panels. On particularly deep voids, which require support, props in excess of standard heights consideration should be given to the use of diagonal bracing.



1.7.5.4. Tolerances

Panels shall be rigidly supported such that they do not rock on their supports, and that tolerances in level between the top surfaces of adjacent panels do not exceed 0.5 mm, and the whole floor shall be level within a tolerance no greater than 2.50 mm in 12 m. 1.7.6. DESIGN CONDITIONS The environmental conditions to which the floor will be subjected will be in accordance with criteria stipulated in the HVAC Design Specification. 1.7.7. MATERIALS All materials shall be new. All materials, or groups of materials for separate installation, shall be clearly identified by tagging and/or color coding to show the building or room into which they are to be installed. Materials such as floor coverings shall be in the form of a color scheme, which will consist of sample board of the material to be used. 1.7.8. FABRICATION 1.7.8.1. Floor Panel or Tray The floor panels shall be nominally 600 x 600 mm. Projecting steel flanges on the underside of the panels shall support all four (4) edges and provide the perimeter support to minimize panel edge deflection where stringers are not supplied as an integral part of the composite construction. 1.7.8.2. Floor Panel Covering

The surface covering of finished floor material shall be pressure applied to the panel and the panel shall be edged with rigid PVC lipping to all four sides. The lipping shall be planed to finish flush with the surface covering. 1.7.8.3. Floor Panel Soffit Treatment The underside, and all four vertical edges of each panel, shall be protected to "Class 1" Surface Spread of Flame in accordance with the fire rating requirements of BS 476, Part 7, or "Class O" of the Building Regulations 1985 Section B. 1.7.8.4. Electrical Earthing The floor shall provide continuous electrical Earthing when the panels are located into their pedestals or into their structural grid. The floor system must comply with the Conductivity/Resistivity requirements for static electricity, which is 1 x 1010 ohms maximum, and 3 x 105 ohm minimum resistance measured from floor surface to building earth. 1.7.9. INSPECTION REQUIREMENTS The Contractor shall advise with reasonable notice of the times when inspection may take place at the Suppliers works.



1.7.10. TESTING The Contractor shall demonstrate that the floor system is capable of carrying the specified loads without showing signs of distress, or being beyond the limits stated in Clause 5.0 of this specification. A deflection in excess of span/100 will be considered as adequate reason for rejection. All loads shall be fully recorded and will act as certification for the floor system. 1.7.11. PROTECTION OF METAL SURFACES All steel parts shall be galvanized in accordance with requirements of BS 2989. 1.7.12. PREPARATION FOR SHIPMENT All items shall be wrapped in polythene film and be packed in timber crates so as to ensure safety and protection in transit. 1.7.13. STORAGE REQUIREMENTS It is intended that this equipment will be stored in a ventilated store protected from the elements. Installation of the floor will not commence until building has been essentially completed in the areas of installation other than for "clean", "dry" finishing and painting. 1.7.14. INSTALLATION OF THE FLOOR The panels shall be left free of all surplus adhesive or defects, and all panels and PVC edging shall be flush and close fitting. The assembled floor system shall be reasonably rigid in all directions and be capable of withstanding, without sway or collapse, a seismic force in any horizontal direction of 0.07g. The clear head between sub floor and raised floor shall be minimum of 1000 mm. The pedestals shall be capable of height adjustment to accommodate a ± 50 mm (2 inches) variation of the sub-floor. All pedestals shall be mechanically fixed to the sub-floor using an approved fixing device. Such a device would be expanding bolts to the approval of the FEWA Engineer. Additional half-posts or pedestals shall be provided to independently support the cut tiles around the edges of the floor. Floor panels shall not be supported on shelf angles fixed to the building structure. The Contractor shall, upon completion, remove all debris resulting from his work and leave the floor complete and to the entire satisfaction of the FEWA Engineer. The sub-floor shall be flat, smooth, and dust-free condition. A good quality tamped finish shall be considered adequate where the floor is concrete.





8. STEELWORK AND PAINTING



TABLE OF CONTENTS

Page 1.8. STEELWORK AND PAINTING............................................................................. 123

1.8.1. Steelwork and Painting ......................................................................................... 123

1.8.2. Structural Steelwork (including miscellaneous steelwork items)......................... 123

1.8.3. Rolled Steel Sections ........................................................................................... 124

1.8.4. Cold Rolled Sections ............................................................................................ 124

1.8.5. Bolts...................................................................................................................... 124

1.8.6. High Strength Friction Grip Bolts .......................................................................... 124

1.8.7. Shop Welding ....................................................................................................... 124

1.8.8. Site Welding.......................................................................................................... 124

1.8.9. Cleaning, Protection and Painting ........................................................................ 125

1.8.9.1. General .................................................................................................................125

1.8.9.2. Preparation of Surfaces........................................................................................125

1.8.10. Painting and Protection......................................................................................... 126

1.8.10.1. Application of Paint Systems - General................................................................127

1.8.10.2. Structural Steel and Associated Items .................................................................127

1.8.11. Protection and Painting of Metallic Materials ........................................................ 129



1.8. STEELWORK AND PAINTING 1.8.1. STEELWORK AND PAINTING 1.8.2. STRUCTURAL STEELWORK (INCLUDING MISCELLANEOUS

STEELWORK ITEMS) Structural steel shall comply with the requirement of BS 4360. The grades shall be as follows: Mild steel - Grade 43A High yield steel - Grade 50B The requirements of which shall be held to include steel less than 6 mm thick. Mill test certificate shall be provided for items of structural steelwork used in the Works. The Contractor shall arrange for the submission of all designs and fabrication drawings for the whole of the steelwork to the FEWA Engineer for his approval. All such drawings shall show the dimensions of all parts, method of construction, spacing of bolts, welded sectional areas and all other details. Bolted or welded construction may be employed, subject to approval and neatness of design. Where welds are used either at Works or on site, they shall wherever possible, be continuous and returned round any meeting face to ensure that the joint is completely sealed against corrosion. Space welds will not normally be accepted without the specific approval of the FEWA Engineer. All welders shall be suitably qualified to the appropriate code requirements and all welding procedures shall be submitted to the FEWA Engineer for approval as required by sub clauses (Shop Welding) and (Site Welding). The details of connections on drawings shall be such as to avoid formation of pockets to hold condensation, water or dirt and a 6 mm minimum gap between abutting ends of bolted members and the like shall be provided to eliminate any traps and facilitate maintenance painting. Gaps between adjacent members shall be either sealed or wide enough to permit maintenance painting. Materials shall not be ordered nor fabrication commenced until the FEWA Engineer approves such drawings. Tests, in accordance with British Standards, shall be carried out. These shall be done in the presence of the FEWA Engineer if so required. All members of prefabricated frames shall be cut to jig and all holes shall be punched or drilled to jig. All parts shall be carefully cut and holes accurately located so that when the members are in position the holes will be truly opposite to each other before being bolted up. The drilling, punching, cutting and bending of all fabricated steelwork shall be such as to prevent any possibility of irregularity occurring which might introduce difficulties in the erection of the structures on the Site.



The work of fabrication and erection shall be carried out in accordance with BS 5950 part 2. 1.8.3. ROLLED STEEL SECTIONS Rolled steel section shall comply with BS 4 and BS 4848. 1.8.4. COLD ROLLED SECTIONS Cold rolled sections shall comply with BS 2994 and shall be made from hot dip zinc coated steel to BS 2989 Grade Z35 coating type G600 surface finish N. Proprietary cold-formed sections for secondary structural components shall be made from hot dip zinc coated steel sheet to BS 2989, Grade Z25, coating type G350 surface finish N. Cold formed sections shall not be used for the main structural frame or bracing. 1.8.5. BOLTS Bolts shall comply with BS 3692, BS 4395, BS 4190 as appropriate. All bolts shall be galvanized and after erection, be painted according to sub clause (Structural Steel and Associated Items). 1.8.6. HIGH STRENGTH FRICTION GRIP BOLTS High strength friction grip bolts shall be tightened in accordance with BS 4604 or use of load indicating washers. 1.8.7. SHOP WELDING All shop welds shall be carried out by welders qualified for the work, under proper supervision and in accordance with BS 5135. The FEWA Engineer may call for a test of a welder's capabilities though machine welding should be used whenever possible. Welders must have been tested within a period of 12 months before welding operations start, to BS 4872: Part 1 using the same class of electrodes and welding positions which will be used in the work. The work shall be properly prepared for welding and all welding procedures shall be submitted for the FEWA Engineer's approval prior to the start of welding. It is expected that all fabrication welding will be carried out in a correctly sequenced manner to minimize distortion and/or potential cracking. 1.8.8. SITE WELDING All site welding shall be carried out by the manual metal arc or tungsten inert gas processes and the root runs of all full penetration but welds shall be made by the tungsten inert gas process. All manual metal arc welding shall be carried out using coated electrodes of the low hydrogen type and the Contractor shall submit his proposals for the receipt, storage, drying, issue and return to store for all approved welding consumables to be used on Site. The welding plant shall be of modern design and of ample capacity to provide the required current to each welding point without appreciable fluctuations. Site welding of high yield steel will not be permitted without the FEWA Engineer's consent. The welding procedure for making each joint shall be approved by the FEWA Engineer before the work is started and the Contractor shall make such trial welds as the FEWA



Engineer may require to demonstrate the soundness of the proposed method and the competence of its workmen. The FEWA Engineer may require such Site made test welds to be radio graphed and/or subjected to bend or impact testing as deemed necessary. Input testing where required by the appropriate code or by the FEWA Engineer shall be carried out to the requirements of an approved specification. Mill test certificates shall be provided for all high tensile steel to be welded and the mill test certificate identification shall be included on the certificates issued for the weld tests required. Whenever possible all welding shall be done in the down hand or horizontal-vertical positions. All parts to be welded shall be accurately prepared in accordance with the requirements of the appropriate code and/or weld geometry so that on assembly they will fit closely together as specified in the code. After assembly and before the general welding is commenced, the parts may be held together for welding by the use of mechanical clamps and/or tack welds. Tack welds should be of sufficient size to fulfill their function and small enough to be fully and properly incorporated into the weld without cracking and/or other defects. If mechanical clamps and/or restraints are employed, care shall be exercised in determining their location and the potential effects on weld cracking and/or distortion. 1.8.9. CLEANING, PROTECTION AND PAINTING 1.8.9.1. General The protection of all items of LDC Building, supporting metal-work, structures, pipe work and other metallic items, including bolts and fasteners, is essential to ensure the area as a whole operates efficiently and in accordance with the design requirements. All ladders, stairs, handrails, platforms, kick plates etc are to be galvanized to BS 729 and painted. The Contractor, or its protection sub-contractor, is required to acquaint itself fully with the prevailing environmental conditions at site to ensure he is capable in every respect of carrying out the protective coating works in accordance with the Specification. All paint systems; paint specifications and other material specifications shall be submitted to the FEWA Engineer for approval before commencement of work. The painting system and finish used for both internal and external surfaces shall be suitable for the particular conditions to be experienced in shipping, storing, erection, commissioning and operation. Where the surfaces to be painted are subject to heat or attack by chemicals, oil, acid, fumes or other aggressive agents, special paints having the appropriate resistant qualities shall be used. The different paints used for priming, undercoat and finish at Works and Site shall all be mutually compatible. Protection of steelwork by painting or any other finish shall not be considered as a substitute for any corrosion allowance specified for any particular applications. Final painting shall be done to the color code, the details of which will be advised during the term of the Contract. The painting system and finish proposed for the different items of equipment are to be listed. 1.8.9.2. Preparation of Surfaces



New unprimed iron and steel surfaces shall be thoroughly cleaned to remove all dirt, grease, condensation and moisture. An approved process such as shot blasting or pickling shall be carried out remove rust and mill scale. Surfaces shall be grit blasted to a minimum finish of ASa2½ of the Swedish Standard Institution (S.I.S. 05.59.00). Using cast steel shot between graded S.170 and S.370. Slag shall not be used to clean any surface except structural steelwork without the specific approval of the FEWA Engineer. In the case of structural steelwork including equipment supports and pipe trestles, it is essential that regular checks for retained mill scale should be carried out using copper sulphate. Tenacious mill scale may take on the appearance of a bright metallic surface after shot blasting and subsequently disrupt the paint protection if not completely removed. The surface profile achieved by blast cleaning shall be appropriate for the protection to be applied. In the case of structural steelwork the surface amplitude from peak to adjacent valley shall not exceed 0.07 mm with a maximum of 0.10 mm. In all cases where the surface profile is considered to be coarser than that necessary to give an over-peak paint film thickness within the range specified by the paint manufacturer for the particular paint, one additional coat shall be applied. Areas of severe profile damage which after blast cleaning will not meet the necessary surface profile requirements shall be ground to a uniform smooth finish prior to re-shot blasting to the correct profile. If such grinding significantly reduces the local thickness, the item will not be accepted. All blast cleaning and preparation operations shall be carried out by skilled operators and on completion of cleaning, all spent shot, oxides and dust shall be effectively removed by vacuum cleaner or other approved means. If any foreign material is trapped in or under the paint cover, the affected area shall be re-blasted to the FEWA Engineer's satisfaction and repainted with the appropriate paint. Surfaces, which have been previously painted, shall be thoroughly cleaned and all loosely adhering defective paint shall be removed by cleaning back to firm edges or shall be completely stripped if necessary. All such areas shall be repainted with the original paint prior to any application of new coats. All rust or loose scale shall be completely removed by an approved process to clean metal. All bare metal shall be appropriately primed in an approved manner. If the primed and/or painted surfaces have deteriorated by overall rust spotting to a state, which in the opinion of the FEWA Engineer is not suitable for local repair, the whole of the affected surface shall be blast cleaned and primed or painted to the original specification. Where they are to be eventually painted, unpainted aluminium alloy surfaces shall be cleaned down to remove dirt and grease and then shall be painted with an approved etching primer. Surfaces to be painted shall have surplus paint removed by cleaning to a firm edge. The appropriate primer shall then be applied as soon as possible. Lead and copper pipes and/or surfaces shall be thoroughly cleaned with abrasive paper and white spirit prior to application of the approved paint system. When copper pipes are to be lacquered these shall be cleaned immediately prior to application of the lacquer. 1.8.10. PAINTING AND PROTECTION



1.8.10.1. Application of Paint Systems - General All paints shall be applied evenly to completely cover the surface. Painting of machinery and auxiliary compartments is to be done by hand and the use of paint spraying equipment is not allowed. Prior to painting by hand, all rubber components, moving spindles, gauges control, governors, and sight gauges and similar items, are to be properly masked. Each coat shall be allowed to harden before any subsequent coat is applied and all work shall be properly cleaned and prepared prior to the application of any paint. The paint manufacturer's instructions including but not limited to paint thickness, drying and over coating times and method of application, must be rigidly adhered to. Successive paint coats shall be of differing colors. Detailed schedules of painting and protection will be required at the design stage and should include all relevant information on the paints proposed, including manufacturers data sheets, the stages of application and the proposed inspection and repair procedures. As an integral part of the exercise, the FEWA Engineer may require test plates to be prepared and exposed at relevant on Site locations before approval for the use of specific paints or paint systems is given. No paints or protective other than those scheduled and approved by the FEWA Engineer shall be used. In all cases the approved paints and protection, including decorative and identification paints shall be applied strictly in accordance with the approved manufacturer's instructions. Skilled operators with appropriate supervision shall carry out all painting and protection works. Painting shall not be permitted during adverse weather and/ or atmospheric conditions such when the humidity is greater than 70%, in rain or fog, at low temperatures, when surface temperatures are less than 3°C above the dew point or when the metal temperature is higher than 50°C. Painting shall not be carried out when the surface to be painted is exposed to direct sunlight. Paint thinners shall only be added to paints in strict accordance with the approved manufacturer’s instructions and viscosity tests shall be carried out on random samples of mixed paints as directed by the FEWA Engineer. Except as herein specified, no paint shall be applied to any surface when it is in the slightest degree damp and any paint so applied shall be removed and replaced to the FEWA Engineers satisfaction at the Contractor's cost. All precautions necessary shall be taken to prevent dust, dirt and moisture from coming into contact with freshly painted surfaces or with surfaces being painted. All grit, shot or other cleaning processes shall be screened off from painting areas and all dust, residues and grit or shot shall be removed prior to painting in any designated area. Attention is drawn to the specific requirements for painting and protection in the following sections. 1.8.10.2. Structural Steel and Associated Items



The surfaces of all structural steelwork, including plant support steelwork, pipe trestles and associated items, steel stairs, galleries and handrails shall be protected by galvanizing and a compatible paint system to take account of specific aggressive conditions. Particular care shall be taken, for example by the application of a stripe coat, to maintain strong paint films on all cleats, arises, boltholes, bolt heads and similar items. Second and subsequent coats shall only be applied when the previous coats have dried and hardened and the manufacturer's instructions for curing are to be strictly observed. A suitable drying and curing time is to be allowed before packing for shipment. The Contractor shall ensure the suitable precautions shall be taken in bundling, packing and crating for shipment to ensure that the protective treatment applied prior to shipment is not damaged during transport to the Site. Straps, rope, wire or chain slings used for handling shall be properly padded or wrapped to minimize damage in handling. All steelwork, including plant support steelwork, and gratings, not fully encased in concrete shall be protected by a system similar to or better than that detailed below: a) For steelwork inside buildings: (i) Shot blast as previously specified. (ii) Hot dipped galvanized conforming to ASTM A123 (for structural steel/ASTM A153

(for fastener) and the minimum coating shall be 915gm/sq.m. (120 microns coating thickness)

(iii) Prime Coat: single pack inorganic zinc silicate solids volume 55 - 60% dry film thickness (dft) 75 microns

(iv) Undercoat: two-pack epoxy polymide solids volume 60 - 65% dft 125 microns At Site: (i) Thoroughly wash with clean water to remove all traces of salts, make good damage

by shot blasting as necessary and repair prime coat with materials as above. (ii) Top Coat: two-pack aliphatic polyurethane solids Volume 45% dft 50 microns (iii) After erection make good all damage by blast cleaning as necessary and building

the whole system to completion. b) Steelwork for stairs, hand railing, ladders etc. and all external structures shall be: (i) Shot blast as previously specified (ii) Hot dipped galvanized conforming to ASTM A123 (for structural steel/ASTM A153

(for fastener) and the minimum coating shall be 915 gm/sq.m. (120 microns coating thickness)

(iii) Degrease, apply mordant wash and etch primer. (iv) Prime coat Single pack inorganic zinc silicate solids volume 55-60% dry film thickness (dft) 75 microns.

(v) Undercoat Two-pack epoxy polymide

solids volume 45-50% dft 125 microns. (iv) Thoroughly wash with clean water, sweep blast if required for adhesion, apply two-

pack aliphatic polyurethane, solids volume 45%, dft 50 microns).



1.8.11. PROTECTION AND PAINTING OF METALLIC MATERIALS Structural and holding down bolts shall be hot dip spun galvanized to BS 729 minimum

average coating 305 g/m2

and painted as for adjacent galvanized steelwork. The nuts shall be hot dipped and reamed out of newly threaded blank nuts, which have been not dipped. Steelwork partially encased in concrete or block work shall be protected at the junction by a strip of approved alkali resistant mastic filler. Machinery and cubicles, particularly of pressed metal may require additional paint treatment unless the manufacturer's standard finish is shown to be adequate and sufficiently durable for the duty. Aluminium, unless of an alloy or grade resistant to corrosion, shall anodized to 40 microns or be adequately primed and painted or otherwise surface treated to provide the required durability. Aluminium for external architectural applications shall have a natural anodized finish and the thickness of the anodizing shall not be less than 40 microns. The surface of copper pipes, brass fittings and similar items, shall be washed with pure white spirit, rubbed with fine emery paper and shall be painted with one coat zinc chromate primer two undercoats and once high gloss finishing coat. The paint type shall be suitable for the expected atmospheric conditions and alkyd base paint shall not be used for items exposed to outside environments. All dissimilar metal contacts should be designed and/or protected with due regard for the potential electrochemical corrosion possibilities. For all noncurrent carrying applications, it is expected that metal-to-metal contact between dissimilar metals will be avoided by the use of suitable electrical insulation. Particular care should be taken in the use of aluminum, zinc, copper, nickel and their alloys in contact with each other or in contact with ferritic materials. Care should also be exercised in the use of these materials in contact with each other or in contact with ferritic materials in contact with alkaline solution, and/or materials. (Concrete, lime, plaster and cement) and in the exposure of such materials or material couples in rainwater drains and run offs from materials, which could impart either acidic or alkaline characteristics to the water. Material to be isolated/insulated from Aluminium and Zinc Copper and its alloys Nickel and its alloys Steel and its alloys (also as below) Non-ferrous metal generally Alkalis (concrete, cement, lime, and plaster). In addition to the above, protection shall be provided from rainwater run off from aggressive materials. Where non-ferrous metals are to be painted they shall be treated in the same way as ferrous materials, above the priming coat. All non-ferrous metals shall be thoroughly degreased before painting in a solvent bath vapor degreaser or other means approved by the FEWA Engineer. The Contractor's attention is drawn to the importance of proper degreasing for non-ferrous metals. Any defective paintwork resulting from inadequate degreasing shall be stripped off, the metal degreased properly and the paint system reapplied at the Contractor's cost.



Non-ferrous metals generally shall be treated up to and including the priming coat as follows: Preparation Metal Factory Site Suitable Primers

Aluminum Phosphating Acid or Degreasing compounds Etch-primer (not after

(Smooth surface,

alkalichromate baths Emery and white spirit (not phosphating).

e.g., sheet Anodising (mainly as wire wool) Phosphoric acid Zinc chromate (not extrusions alternative to treatments. lead-based primer). aluminised painting). steel).

Aluminium Smooth off nibs with Smooth off nibs with emery Etch-primer Zinc

(rough surface emery paper. Clean paper. Clean off dust and chromate (not lead- e.g., castings off dust and dirt. dirt. based and sprayed metal) primer).

Zinc (sheet hot- Degrease Phosphate

Degrease with white spirit. Calcium plubate etch-

dipped and/or chromate Weathering for at least primer (not after galvanised or treatments. several months plus phosphating) electro- washing. Phosphoric acid Zinc chromate primer galvanized) treatment (not as effective Zinc dust/zinc oxide as factory processed). primer or Zinc rich paint. Zinc (sprayed or Clean off dust and Clean off dust and dirt. Etch-primer sherardised dirt. (preferably plus Zinc coatings) chromate primer).

Copper (also Special processes Emery and white spirit. Etch-primer Aluminum

brass and Electro-deposited tin.

pigmented primer.

bronze)

Tin coatings Degreasing Light abrasion (do not Etch-primer Zinc

abrade through coating). chromate. Degrease with white spirit.

Cadmium (coatings)

Phosphating Emery and white spirit. Etch-primer.



9. ROADS AND SURFACING



TABLE OF CONTENTS

Page 1.9. ROADS AND SURFACING ..................................................................................133

1.9.1. Roads and Surfacing............................................................................................133

1.9.1.1. Compaction of Sub-grade ....................................................................................133

1.9.1.2. Tests for Sub-Grade.............................................................................................133

1.9.1.3. Sub-Base..............................................................................................................134

1.9.1.4. Wet Mix Road Base..............................................................................................134

1.9.1.5. Chlorides and Sulphates ......................................................................................135

1.9.1.6. Placing of Road Base...........................................................................................136

1.9.1.7. Hard Shoulders.....................................................................................................136

1.9.1.8. Tests on Sub-Base and Road Base ....................................................................137

1.9.1.9. Frequency of Testing............................................................................................137

1.9.1.10. Bitumen Macadam................................................................................................137

1.9.1.11. Design of Bitumen Macadam...............................................................................139

1.9.1.12. Mixing and Laying..................................................................................................140

1.9.1.13. Testing of Bitumen Macadam...............................................................................143

1.9.1.14. Final Surfacing......................................................................................................144

1.9.1.15. Jointing new to Existing Pavement.......................................................................144

1.9.1.16. Overlays................................................................................................................144

1.9.1.17. Interlocking Paving Blocks....................................................................................144

1.9.1.18. Site Surfacing .......................................................................................................145

1.9.1.19. Sampling and Testing of Materials Used in the Construction of Roads...............145

1.9.1.20. Kerbs ....................................................................................................................146

1.9.1.21. Traffic Signs..........................................................................................................146

1.9.1.22. Carriageway Markings ..........................................................................................147

1.9.1.23. Concrete Paving Slabs.........................................................................................147

1.9.1.24. Temporary Traffic Signs and Carriageway Markings...........................................147



1.9. ROADS AND SURFACING 1.9.1. ROADS AND SURFACING 1.9.1.1. Compaction of Sub-grade The area of the Works shall be cleared of any material or obstructions, which in the opinion of the FEWA Engineer might adversely affect the stability of the fill or pavement, and the top layer removed to a depth of 300 mm (or more if the design so required). The sub-grade and formation shall be checked and accepted by the FEWA Engineer before placing and spreading operations are started. Any ruts or soft areas caused by improper drainage conditions, hauling or any other cause shall be corrected and rolled to the required compaction before sub-base is placed thereon. The formation shall be compacted to a dry density of at least 98% of the maximum dry density as determined in BS 1377: Test 13 (BS 'Heavy' compaction) and a CBR of 15%. Where the Contractor is unable to achieve this degree of compaction to the formation level further excavation shall be carried out to a depth to be defined by the FEWA Engineer (but not less than 300 mm). Selected backfill will thereafter be placed and compacted to the requirements of this Clause. Where the land contours require it fill in embankment shall be placed and compacted with minimum embankment slope of 1: 4. Compaction shall be carried out by means approved by the FEWA Engineer. All construction equipment must operate over the full width of the formation to ensure uniform compaction. 1.9.1.2. Tests for Sub-Grade The sub-grade compaction test shall be modified AASTHO compaction test as described in BS 1377: Test 13, and shall be carried out in a mould 10 cm internal diameter and 12.5 cm internal height. The mould shall be filled in five equal layers, each layer being given 25 blows of a 4.5 kg hammer falling freely for 45 cm. Except when otherwise specified, the CBR specimens shall be soaked for 96 hours or such other period of soaking as may be determined by the FEWA Engineer to correspond with the moisture content pertaining under the most unfavorable conditions to which the material may be subjected. Laboratory tests shall be done using surcharge weights as required by the FEWA Engineer. If due to the high proportion of granular material retained on the BS 19 mm sieve, or for other reason, the FEWA Engineer may elect to measure sub-grade compaction by the vibrating hammer method of using a CBR mould as in BS 1377: Test 14. The compaction requirements measured by this means shall be taken as that stipulated for the compaction test plus 5%. In-situ dry density tests on each layer of compacted material shall be carried out at an average of not less than 2 per 100 m length of carriageway. In-situ CBR tests shall be carried out as directed by the FEWA Engineer. Where any test fails, removal of unsuitable material and/or re-compaction will be carried out over an extent as required by the FEWA Engineer. Retesting will then be required.



Classification tests shall be carried out as necessary to ensure that true comparisons can be made between in-situ densities, laboratory compaction densities and field trial densities, i.e., those variations in the properties of materials being used in the test are not affecting results. Each in-situ dry density result shall be the mean of the in-situ dry density result shall be the mean of the in-situ dry density of three close test holes approximately 0.5 m apart. 1.9.1.3. Sub-Base Sub-base material shall be crushed rock or other approved local material having suitable properties and confirming to the following grading: B.S. Sieve Size Percentage by Weight mm Passing 75 100 37.5 85 - 100 10 45 -100 5 25 -85 0.6 8 - 45 0.075 0 - 10 When tested to BS 882 the material shall have a minimum "ten percent fines" value of 5. The material passing the 0.425 sieves shall have a plasticity index of less than 6. The material shall be spread evenly on the preceding material in layers not exceeding 200 mm-compacted thickness. Segregation shall be avoided during transport and placing and any segregation evident after compaction shall be corrected by vibrating in fines or made good by removing and replacing with properly graded material. If necessary the material shall be spread using a spreader box or paving machine to minimize segregation and enable an even depth and the level tolerance to be achieved. The sub-base shall be compacted by approved plant to a dry density, which shall not be less than 98% relative compaction until movement of the surface ceases, and the surface is closed. The CBR value shall be at least 30% at the maximum moisture content, which in the opinion of the FEWA Engineer will occur after completion of the Works. Where the sub-grade can be compacted as specified by available plant to give a stable well knit surface which will resist deformation during sub-base placing and with in-situ CBR values of greater than 30%, then the sub-base layer may be reduced to 100 mm thickness at the option of the FEWA Engineer. 1.9.1.4. Wet Mix Road Base Wet Mix road base material shall consist of crushed gravel or crushed rock and shall be suitably proportioned to confirm to the following grading as approved by the FEWA Engineer. B.S. Sieve Size Percentage by Weight mm Passing 50 100 37.5 90 –100 20 60 –80



10 40 –60 5.00 25 - 40 2.36 15 - 30 0.600 8 - 22 0.75 0 - 8 The fraction passing the 0.075 mm sieve shall not be greater than two-thirds of the fraction passing the 0.425 mm sieve. Material constituents shall comply with the following maximum limits: For material passing the 0.425 mm sieve: Liquid limit 25% Linear shrinkage 3% Plasticity index 6% For coarse material: Stone Size Aggregate 50 mm Aggregate crushing Value 25%

Water absorption 2%

Flakiness index 35%

Elongation index 35%

Mg SO4 soundness 15%

Quarry won material shall be extracted from faces and areas approved by the FEWA Engineer. The aggregate crushing value shall be monitored by regular testing of material prior to its inclusion in the construction. The material shall be spread evenly on the sub-base in layers not exceeding 200 mm-compacted thickness. Segregation shall be avoided during transport and placing and any segregation evident after compaction shall be corrected by vibrating in non-plastic fines or made good by removing and replacing with properly graded material. The base shall be compacted by approved plant to a dry density, which shall be not less than 98% relative compaction, and until movement of the surface ceases and the surface is closed. The completed layer shall have an in-situ CBR of not less than 80%. The final surface shall be shaped and finished true to line and level within a tolerance of ± 10 mm to the levels shown on the drawings. 1.9.1.5. Chlorides and Sulphates The level of the acid-soluble chloride (as NaCl) (BS 812: Part 117) in the subbase and road base layers shall not exceed 3.5% and 0.5% by weight respectively. The level of acid-soluble sulphate (as SO3) (BS 812: Part 118) in the sub-base and road base layers shall not exceed 2.0% and 0.5% by weight respectively.



Potable water shall be used for compaction purposes. 1.9.1.6. Placing of Road Base Wet mix road base material shall be crushed and mixed by approved mechanical Placing plant. Water for adjusting the moisture content shall be added at the mixer. Wet-mix. If required, the moisture content shall be adjusted to allow for evaporation Road base loss during transportation. After mixing, the material shall be removed from the mixer and transported to the placing location without delay. The moisture content at the time of laying shall be within ± 0.5% of the optimum value determined in accordance with the Vibrating Hammer Method described in BA 1377, Test 14. Vehicles carrying the plant-mixed material shall be of a capacity suited to the output of the mixing plant and the site conditions, and shall be capable of discharging cleanly. After mixing is complete, the materials shall be removed at once from the mixer, transported directly to the point where it is to be laid and protected from the weather both during transit from the mixer to the laying site and whilst waiting tipping. The distance between mixing plant and job site shall not exceed 20 km. The compaction procedure and plant shall be proved by trials at the commencement of the Works. The weight, type and number of passes of compaction plant shall be varied to determine the optimum compaction effort. Road base material shall be placed and spread evenly, without delay, using a paving machine, or spreader box operated with a mechanism which level off the material at an even depth and it shall be spread in layers not exceed 200 mm compacted thickness. Segregation shall be made good by removal and replacement. The road base shall achieve a minimum dry density of 98% of the maximum laboratory dry density and an in-situ CBR value of not less than 80%. Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and transverse joints. The completed surfaces of all layers shall be well closed and free from movement under compaction plant, and shall have no compaction planes, ridges, cracks or loose material. All loose segregated or otherwise defective areas shall be made good to the full thickness of the layer and re-compacted. Before placing the next construction layer or applying prime coat, the road base shall be mechanically swept then cleaned with compressed air to remove loose material. As soon as possible after cleaning of the surface, the road base shall be sealed by the application of a prime coat as specified. Should the surface of the material be allowed to dry out before the seal is applied, it shall be lightly watered and re-compacted immediately prior to spraying with prime coat. Should the full depth of layer be allowed to dry out, it shall be removed and replaced, at the Contractor's expense, with fresh material. Watering and re-mixing in place will not be permitted. 1.9.1.7. Hard Shoulders The material used for any hard shoulders shall comply with the specification for wet-mix road base.



1.9.1.8. Tests on Sub-Base and Road Base Before any section of the roadwork’s is commenced and during its construction, the Contractor shall carry out on the FEWA Engineers instructions tests and control tests to determine the degree of compaction in the sub-grade, sub-base and base. No section of the work shall be covered until the FEWA Engineer has approved it. The FEWA Engineer may make use among others any of the following tests: Density/Moisture tests Compaction tests CBR in-situ test CBR remoulded test The laboratory tests shall be carried out in accordance with BS 1377. The specified requirements must be achieved in each successive layer. Checking that the specified requirements have been attained in lower layers after higher layers have been placed will not be accepted, except where existing road surfaces have been removed. Any departure from the method of constructing in layers will not be permitted. The results of control tests shall be furnished daily to the FEWA Engineer. The Contractor shall be responsible for the cost and execution of all density tests, moisture tests and CBR tests necessary in establishing the compaction procedure and subsequent control tests required by the FEWA Engineer. 1.9.1.9. Frequency of Testing In-situ dry density tests on each layer of compacted material shall be carried out at an average of not less than 2 per 100 m length or carriageway. In-situ CBR tests shall be carried out as directed by the FEWA Engineer. Classification tests shall be carried out as necessary to ensure that true comparisons can be made between in-situ densities, laboratory compaction densities and field trial densities, i.e. that variations in the properties of materials being used in the tests are not affecting results. The compaction procedure and plant shall be proved by trials at the commencement of the Works for approval by the FEWA Engineer. Compaction trials shall be carried out at varying moisture contents. The weights, types and numbers of passes of compaction plant shall also be varied to determine the optimum compactive efforts. No traffic shall be permitted on the completed base in excess on the minimum required to place the overlying construction. 1.9.1.10. Bitumen Macadam Aggregate shall be hard, clean, durable crushed rock or gravel, and sand all in accordance with BS 4987 and shall be obtained from approved source which shall not include quarries containing significant proportions of weather bed, decomposed or extensively fractured materials. The Contractor shall propose a suitable source, or sources, and samples shall be obtained for specified testing before arrangements for obtaining aggregate are



approved. Laboratory tests shall be made at regular intervals to confirm the suitability of aggregate. The Contractor shall obtain whatever permissions are necessary for the exploitation of quarries and borrow-pits and shall pay royalties, fees, way leaves and the like. The Contractor shall operate the quarry or pit in an approved manner and provide sufficient evidence by means of boreholes, test holes and the like to show that the quarry contains aggregate of the required quality and quantity to complete the Works, and he may be required to produce a geological map. The aggregate winning and processing operations shall not constitute a danger to health or safety either during or after completion of the Works, nor interfere with others. When quarrying operations are complete, the Contractor shall leave the quarry in a safe condition by, inter alia: a) Barring down all faces so that no loose rock remains on any face. b) Bringing down overhanging rock safely. c) Ensuring that the quarry is free draining and that no water can accumulate; or, in

the case of a quarry below ground level, minimizing the accumulation of water and draining to approved areas. Warning notices in Arabic and English may be required at any concentrations of water, which constitute a hazard.

d) Stockpiling surplus rock material to a height not greater than 5 meters with stable side slopes.

Aggregate and chippings for surface dressing, shall be stored so that segregation, intermixing of different aggregates and contamination by dirt and other foreign materials is prevented. In general, each size of aggregate shall be stored separately. Coarse aggregate is defined as that fraction retained on a 3.5mm BS sieve. It shall have physical properties, which do not exceed the following test values when tested in accordance with BS 812: Wearing Base course Course Aggregate crushing value 20% 25% Flakiness index 25% 30% Elongation index 25% 30% Water absorption 2% 2% Coarse aggregate may contain up to 15% of pieces with one uncrushed face in each grading size when tested in accordance with Test Method DM-301. Aggregate obtained from quarried rock shall be deemed to satisfy this requirement. Separate coarse and fine aggregate fractions shall be tested for soundness in accordance with ASTM C 88. After 5 cycles of immersion in magnesium sulphate solution and drying, the loss of weight expressed as a percentage of the initial weight shall not exceed 12%. Any filler, if approved for use, shall comply with BS 4987 (1973). The aggregate grading for binder shall comply with the following: Finished thickness of binder (mm) Grading [BS 4987 (1973)] 60 Table 21



Wearing course shall be of 40mm finished thickness; the aggregate grading shall be as follows: BS Test Sieve (mm) Grading (20mm nominal size) % by weight passing 28 100 20 95 –100 14 70 –90 10 55 –75 6.3 40 –60 3.35 25 –40 1.18 15 -30 0.075 2 - 6 Bitumen shall be of Grade 60/70 penetration with properties corresponding to an interpolation between Grade 50 and Grade 70 as defined in BS 3690. The specific gravity and temperature/viscosity relationship shall be provided. The frequency of testing of the penetration index shall be two tests per delivery of bitumen. The PI range shall be -1 to +1. 1.9.1.11. Design of Bitumen Macadam Design mixes shall be submitted for approval and proved by means of laboratory, plant and field trials. Tracking tests may also be required. The mixes shall be tested in accordance with the following methods: · Preparation and testing of Marshall Specimens: ASTM D 1559 using 75 blows per face. · Bulk Specific Gravity of specimens: ASTM C 1188. · The values for specific gravities of the aggregates to be used in calculating the voids

shall be taken as the mean of the Bulk, Apparent and Effective Specific Gravities as defined in the American Asphalt Institute publication "Mix Design Methods for Asphaltic Concrete."

· The adhesion of bitumen to aggregate shall be proven by comparing the stability of specimens cured in water and air for eight days at 18 degrees C. The ratio of stability in the two shall not be less than 0.65.

· Wearing course mix shall be subjected to further Marshall tests at 80 degrees C after oven heating for a period of 2 hours; the stability/flow ratio shall not fall below 270 at this temperature.

· Mixes with bitumen content corresponding to the maximum allowable for the selected job mix shall be compacted to refusal, or to 600 blows per face whichever shall be reached first, and the resulting voids-in-mix values shall be not less than 3%.

· The designed mixes shall comply with the following: Binder Wearing Course Course Voids in mix (%) 7 - 10 5 – 8 Voids in mixed aggregate % 14 - 20 14 – 20 Minimum stability (kg) 750 1000 Flow (mm) 2 - 4 2 – 4 Minimum stability flow ratio (kg/mm) 270 320 Bitumen content (% of total mix) 3.3 - 4.0 3.5 - 4.2 Voids filled with Bitumen (%) 48 – 60 48 - 60



After a design mix has been approved and adopted as a job mix, the maximum permitted deviations from the job mix shall be as follows: Permitted Deviations Sieve size: 6.3mm or larger ± 5% 3.35mm ± 4% 0.6mm to 1.18mm ± 3% 0.075mm to 0.3mm ± 2% Smaller than 0.075mm ± 1% Bitumen ± 0.2% Voids in mix ± 1% The application of the above deviation percentages shall not result in values falling outside those specified in the clause covering the design and testing of bitumen macadam mixes. Chlorides and Sulphates shall comply with clause 1.05. 1.9.1.12. Mixing and Laying The mixing and placing of bitumen macadam shall be carried out in accordance with the requirements of BS 4987 (1973). The aggregate and bitumen shall be mixed in an approved plant of the batch type. Constituents shall be proportioned by weight; a metering pump may proportion the bitumen. Facilities shall be provided in the mixer to enable the sampling of hot aggregates. Bitumen and aggregates shall not be heated to above 150 degree c and 170 degrees C, respectively, and the temperature difference between them at the time of mixing shall not exceed 15 degrees C. The mixing temperature shall be established from the bitumen viscosity/temperature graph in accordance with ASTM D2170 and ASTM D1559. Approved facilities for continuous measurement of temperature of temperatures shall be provided. The batching plant and equipment shall be properly maintained and cleaned and shall be provided with means of checking the accuracy of weighing mechanisms and metering devices. These shall be checked at monthly intervals or as directed. Bitumen macadam shall be transported in clean vehicles. Dust, coated dust, oil or water may be used on vehicle bodies to facilitate discharge, but the amounts shall be kept to a minimum and any excess shall be removed by tipping or brushing. Heat loss shall be minimized during transit and the macadam shall not be discharged into the pavers at a temperature less than 120 degrees C. Bitumen macadam shall generally be spread, leveled and tamped by approved self-propelled pavers. Immediately after arrival at the site, the macadam shall be supplied continuously to the pavers and placed without delay. The rate of the delivery of material to the pavers shall be regulated so that the pavers may operate continuously and it shall be adjusted to provide an even and uniform flow of material across the full laying width, freedom from dragging or tearing of the material and minimum segregation.



Excess material arising from placing base course shall be removed by brooming or light raking. Over-raking causing segregation of the material shall not occur. The excess shall be discarded and not used elsewhere. Hand-raking or wearing course material, which pavers has laid, and the addition of material by hand spreading for adjustment of level will require prior approval. If the abutting lane or succeeding strip is not placed on the same day, the joint shall be cut back to an even line. Loosened material shall be discarded. The joint shall be brushed with a very light coat of hot bitumen before the next strip is placed. The whole face of the joint shall be treated before fresh macadam is placed against it. Joints shall be formed only in compacted material and fresh material placed against a cut face shall be properly compacted. Joints in wearing course shall be offset by at least 300mm from parallel joints in the layer beneath. Hand laying of macadam will be permitted only for laying courses of irregular shape and varying thickness, and in confined areas where pavers cannot operate. The Contractor shall obtain approval of compaction methods and plant by carrying out trials to demonstrate consistent achievement of the requirements. The degree of compaction achieved during the trials shall be not less that 1% greater than that required during the course of the Works. The methods and plant shall not be changed without approval. After placing, the macadam shall be compacted to the thickness shown on the Drawings by rolling to a density of not less than 98% of the maximum density of the approved daily Marshall Laboratory density. Should any individual core, tested in accordance with the clause titled "Testing of Bitumen Macadam", not have the specified degree of compaction, additional cores may be taken in adjacent locations, at the discretion of the FEWA Engineer. Should the bitumen macadam fail to achieve the specified density, at the discretion of the FEWA Engineer re-rolling may be allow subject to the following conditions. a) The densification to be achieved shall be 1% or less.

b) Only PTRs shall be used, weighing no greater than 18 tones.

c) Re-rolling shall take place within 72 hours after the time of the initial

rolling of the bitumen macadam.

d) Re-rolling shall take place at the time of day when the bitumen macadam

has attained it maximum natural temperature.

e) Re-rolling shall be applied for a maximum of two hours.

f) Re-rolling shall be carried out in the presence of the FEWA Engineer's

Representative and a Representative from the Client's Materials Testing Laboratory.

g) The section of the works in question shall be cored for density



determination immediately after the completion of re-rolling.

h) If, after re-testing, the density achieved is equal to or greater than 99.5%

of the specified density, the bitumen macadam will be accepted in the Works subject to a 20% reduction in the billed rates. If, on other hand the density achieved is less than 99.5% of the specified density, the bitumen macadam shall be removed and new material to the specification laid at the Contractor's cost. Before pavement construction is commenced, a trial area of each pavement materials shall be laid. The extent and location of these areas shall be as approved. The materials, mix proportions, plant and methods shall be those, which are proposed for the main work. A priming coat of grade MC 30 petroleum bitumen shall be applied to the road base at the rate of 0.55-to.7 liter per m2, before placing macadam. The binder course shall not be laid until the priming coat has been cured. The binder course shall be prepared to receive the wearing course by removal of dust and deleterious materials by air jetting or other approved means. A tack coat of grade MC 30 cutback bitumen or SS1H emulsion shall be applied to the binder course at the rate of 0.25 to 0.35 liter per m2 before placing the wearing course. The wearing course shall not be laid until the tack coat has cured. The wearing course shall adhere satisfactorily to the base course. If approval has been given for macadam to be placed at night, approved lighting shall be provided at locations where mixing, laying and testing operations are in progress. The horizontal alignment of the road as constructed shall not deviate by more than ± 10mm from the true alignment as given by the dimensions on the Drawings. The rate of deviation shall not exceed 1 in 1000. The required levels of base course and wearing course shall be determined from the finished road surfaces calculated from the vertical profiles and the cross-falls shown on the Drawings. The permitted vertical deviation from the true level of any point shall be ± 5mm for base course and ± 3mm for wearing course. The thickness of the individual layers of base course and wearing course shall not vary by more than 5 mm from the theoretical thickness of the respective layers. The combined thickness of binding course and wearing course layers shall not vary from the theoretical combined thickness by more than 10% of that thickness, or by 10mm, whichever is less. The numbers of permitted longitudinal irregularities in the wearing course, base course and hard shoulder surfaces shall not exceed the figures in the following table. Wearing Course Binder Course

Irregularity 3 mm 6 mm 4 mm 7 mm

Length m 300 75 75 300 75 300 75 Number of irregularities 20 9 1 40 18 4 2 An irregularity is a variation greater than 3 mm or 7 mm in the longitudinal profile of the road surface as measured from a 3 m long straight edge.



No irregularities exceeding 8 mm shall be permitted. Wearing courses shall also be measured transversely for irregularities by a 3 m straight edge placed at right angle to the center line of the road. The maximum permissible deviation in this case shall not exceed 3 mm. Traffic shall not be allowed to run on any surfaces without approval. 1.9.1.13. Testing of Bitumen Macadam Unless otherwise specified the sampling and testing of bitumen macadam shall be carried out in accordance with the requirements of BS 598. (ASTM 2172 for bitumen content). Frequent testing of the mix and of the compacted macadam shall be carried out to ensure that the design requirements to ensure that the design requirements are being achieved. Aggregate grading shall be checked frequently to ensure that they comply with those used in determining the mixes. The bitumen metering equipment, the bitumen temperature and the temperature of the aggregate at the exit from the dryer shall be regularly tested. Samples for analysis shall be taken from the final mix as it leaves the mixer and from around the augers of and/or behind the pavers. Marshall cylindrical test specimens shall be made from the mix and tested. Cored samples shall be taken after placing and shall be tested in accordance with ASTM D 1188. The entire operation of mixing and compacting bitumen macadam shall be performed under close control. Frequent testing of the mix and of the compacted pavement will be required as the work proceeds to ensure that the design requirements are being maintained. The FEWA Engineer may check the aggregate grading in the various stockpiles to ensure that they comply with those used in determining the mixes. The FEWA Engineer may test the bitumen metering equipment, the bitumen temperature and the temperature of the aggregate at the exit from the dryer. The FEWA Engineer may take samples for analysis from the final mixture both as it leaves the mixer and after it is laid. In particular, Marshall cylindrical test specimens shall be made from the mix and shall be tested to ensure the continuing suitability of the job mix in relation to the design criteria specified herein. The preparation and testing of Marshall cylindrical specimens shall be carried out as specified herein. Specified gravity of the mixed material shall be measured by the ASTM D2041 Standard test and cored samples taken from the compacted pavement to measure in-situ density. The frequency of testing shall be as directed by the FEWA Engineer. In general, routine testing of the mix, which shall include at least, Marshall Type tests, bitumen extraction, and grading tests, shall be carried out at least 4 times a day during full production or at the rate of one sample for every 100 tones produced whichever is the more frequent. Cores shall be cut and tested at the rate of 1 per 500 sq. m. As soon as possible after cutting, core holes shall be painted on their sides with a thin coating of hot bitumen and refilled with bitumen macadam of the appropriate mix. Compaction shall be carried out with a Marshall hammer or other approved means. If tests show that the specified requirements are not achieved, the whole process of mixing and laying bitumen macadam shall be stopped and shall not recommence until corrections



have been made to the methods adopted for mixing and laying that will ensure that the minimum requirements are achieved. 1.9.1.14. Final Surfacing The Bitumen Macadam binder course shall be kept clean and uncontaminated so long as it remains uncovered by a wearing course. Should the binder course become contaminated the Contractor shall make good by cleaning to the satisfaction of the FEWA Engineer and if this is impracticable by removing the layer and replacing it to specification. When all heavy plant has been delivered and all soft, fatty or otherwise objectionable areas of the road have been reinstated and made good to the satisfaction of the FEWA Engineer, the wearing course shall be laid. 1.9.1.15. Jointing new to Existing Pavement Where new pavement is required to join into existing road construction, the joint shall be formed and treated in accordance with the Drawings. Unless shown otherwise on the Drawings, each layer of existing bituminous course shall be cut back to a clean vertical face and coated with hot bitumen of a grade suitable for the purpose immediately before laying adjacent new bituminous material. If cutting back of the existing pavement layers is required to form a stepped pattern, the lower layers of bituminous courses shall be prepared to receive the new covering coats by removal of dust and deleterious materials by air jetting or other approved means, and shall be coated with bituminous tack coat. Exposed existing road base surfaces shall be scarified then re-compacted and sealed with bituminous prime coat in accordance with road base specification. 1.9.1.16. Overlays Overlays shall be placed in accordance with the requirements for placing bitumen macadam. In addition to the requirements for base course preparation, the area to be overlaid shall be cleaned by soaking with potable water and mechanical brushing while wet. This operation shall be carried out twice and shall be followed by air jetting. Where the existing pavement layer is smooth or where bitumen, oil, rubber, dust etc. has accumulated, the area shall be cold-planed to a nominal depth of 10 mm, to provide a key for the overlay. A bituminous tack coat shall be applied to the prepared surface before the overlay is laid. Overlays shall be laid to achieve the minimum specified thickness. Protrusions of the existing pavement shall be removed to give the minimum depth required. Holes and local depressions shall be cut out to at least 25 mm depth and filled with base course or wearing course material, as appropriate, prior to commencement of the overlaying course. 1.9.1.17. Interlocking Paving Blocks



Roads and areas to be paved with interlocking concrete blocks shall be excavated and placed with 300 mm depth of compacted material at the exact levels and falls required for the finished work. If parts of the base are found to be unstable the Contractor shall excavate further to a firm bed and fill with layers of fine crushed rock or aggregate, thoroughly compacted. The upper surface of the base shall reflect the exact profile, fall or contour of the final paving, as irregularities shall not be compensated for by varying the depth of sand bedding. Compaction of formation and base for interlocking concrete slabs shall be as Clauses (Compaction of Sub-Grade), (Road Base), (Tests on Sub-Base and Road Base). A stable edge shall be provided to retain the paving units and sand bedding by means of precast concrete edging unit or kerbs set in-situ concrete. The sand bedding shall be a fine, well graded sand in a dry to moist condition and laid to uncompacted thickness of 50 mm. Samples of the paving blocks are to be submitted to the FEWA Engineer for his approval. No orders shall be placed with the manufacturers until the FEWA Engineer's approval has been given. The mix for paving blocks shall contain a water-repelling additive. The paving blocks shall be laid in accordance with the manufacturers instructions and shall be compacted at completion of each day's work. The interlocking block shall be a minimum of 80 mm thick and the concrete quality shall be to the approval of FEWA Engineer. 1.9.1.18. Site Surfacing Chippings for site surfacing shall consist of a 100 mm thickness of 25 mm uniform gauge crushed and washed gravel as approved by the FEWA Engineer. 1.9.1.19. Sampling and Testing of Materials Used in the Construction of Roads Samples shall be taken in accordance with the relevant British Standard where applicable. Materials subsequently supplied shall at least equal the approved sample in all respects. No source of supply shall be changed without prior written approval from the FEWA Engineer. Any samples not approved or materials failing to comply with the approved samples shall immediately be removed from the site of the Works. The Contractor shall submit to the FEWA Engineer copies of all orders for materials to be incorporated in the Permanent Works if required to do so. All materials to be used in the permanent Works shall be subject to inspection and tests as the work proceeds. The Contractor will be responsible for carrying out all tests required under the Contract or as instructed by the FEWA Engineer from time to time and will provide the necessary laboratory facilities, apparatus, equipment, skilled laboratory staff and labour required for this purpose. The FEWA Engineer and his staff shall have access at all reasonable times to the laboratories, laboratory staff and equipment required for the testing of the Works. The results of control tests shall be furnished to the FEWA Engineer.



1.9.1.20. Kerbs Kerbs, channels, edgings and quadrants shall be cast generally to BS 340 but to the dimensions shown on the drawings where these differ from preferred dimensions list in BS 340. They shall be cast to the required radius for all curves not less than 12 meters. Paving slabs will be to BS 368. Raised kerbs shall be laid with a 6 mm gap and pointed with 1 to 3 polymer modified cement mortar above road level only. Concrete bedding and backing to kerbs shall be cast in-situ to the dimensions shown on the drawings. Flush kerbs shall be similarly laid and jointed or may be cast in-situ. The outside corner of the kerbs shall be chamfered. In the case of precast kerbs one joint in ten shall be left unpointed and 6 mm compressible insert provided, and a construction joint formed in the haunching at this point for expansion. Similarly expansion joints are to be formed in in-situ kerbs at 4.0 m intervals. Marginal strips and kerbs shall be protected against covering or splashing with bitumen or cement. Kerbs and manhole frames shall be primed before bituminous macadam is laid. All raised kerbs shall be alternately painted black and white in the plant area and at junctions. 1.9.1.21. Traffic Signs Traffic signs shall be reflectorised and unless specifically stated to the contrary shall comply with the latest revision of: a) BS 873. b) The "Traffic Signs Regulations and Directions" published by H.M.S.O. c) The "Traffic Signs Manual" published by H.M.S.O. d) Local Traffic Police requirements. The signs and their individual elements shall be capable of withstanding the minimum wind pressure referred to in the design requirements. The Contractor shall design the signs, based on typical details provided by the FEWA Engineer. Number, type and position of the signs to be as agreed with the FEWA Engineer. All signs shall be fabricated from sheet aluminium to BS 1470. Mounting posts shall be of circular hollow steel section structural steel, Grade 43C to BS 4360. Post caps, also of Grade 43 C steel to BS 4360, shall be continuously fillet welded to the post heads to prevent the ingress of water. Single post signs will generally be cast directly into a concrete base but signs having two or more posts shall have suitable base plates for mounding flat down to a previously constructed concrete base. The base plates shall be continuously fillet welded to the posts, shall be suitably stiffened if necessary, and shall be pre-drilled to accommodate holding down bolts.



Where there is a possibility of aluminium and steel coming into contact with each other at fixing points suitable non-degradable inert packing shall be provided to prevent such contact. All steelwork shall be hot-dip galvanized to ASTM A123 and shop painted according to Section G of the Civil Specification in a salt and dust free covered area, the finishing color coats being according to the Local Traffic Authority requirements. 1.9.1.22. Carriageway Markings The material for markings shall be not applied 'Spray-plastic' complying with the requirements of BS 3262, as manufactured by Prismo Universal Limited, or similar approved for use in the tropics. Carriageway markings shall only be applied to surfaces, which are clean and dry. Where owing to the action of traffic or otherwise, the pavement has become polished before the application of road markings, at the direction of the FEWA Engineer a tack coat compatible with the marking material shall be applied in accordance with the manufacturer's instructions. Markings shall be free from raggedness at their edges and shall be uniform and free from streaks. "Ballotini" is to be incorporated at 18% to 22% by weight of total mix and also to be applied to the surface of the markings at the rate of 400 to 500 g/m2. The laid thickness of the markings shall be 1.5 + 0.5 mm measured in accordance with Appendix H of BS 3262. The Contractor shall state the maximum safe heating temperature, the temperature range of the apparatus and the method of laying to be used. 1.9.1.23. Concrete Paving Slabs Areas to be paved with concrete paving slabs shall be excavated and replaced with 300 mm depth of compacted material at the exact levels and falls required for the finished work. If parts of the base are found to be unstable the Contractor shall excavate further to a firm bed and fill with layers of fine crushed rock or aggregate, thoroughly compacted. The upper surface of the base shall reflect the exact profile, fall or contour of the final paving as irregularities shall not be compensated for by varying the depth of sand bedding. Samples of the paving slabs are to be submitted to the FEWA Engineer for his approval. No orders shall be placed with the manufacturers until the FEWA Engineer's approval has been given. The paving slabs shall be laid in accordance with the manufacturer's instructions. 1.9.1.24. Temporary Traffic Signs and Carriageway Markings For road diversions the signs and markings shall generally follow the specification for permanent works. Posts and foundations shall be designed to facilitate re-use but also must be robust.



Warning lights, heavy-duty bollards, etc., are to be provided. All diversion works and the location, quantity and specification for all signs, lights, bollards etc., are to be approved by the local Authorities and the Traffic Police Department.



10. STRUCTURES FOR OUT DOOR EQUIPMENT



TABLE OF CONTENTS

Page 1.10. STRUCTURES FOR OUT DOOR EQUIPMENT ................................................ 152

1.10.1. Design................................................................................................................... 152

1.10.1.1. General .................................................................................................................152

1.10.2. Assumed Working Loads ..................................................................................... 152

1.10.3. Incoming Phase Conductor Details...................................................................... 152

1.10.4. Factors Of Safety ................................................................................................. 153

1.10.5. Load Combinations............................................................................................... 153

1.10.5.1. Normal Conditions – Factor of Safety 1.5 ............................................................153

1.10.5.2. Unbalanced Conditions – Factor of Safety 1.2.....................................................153

1.10.6. Wind Loading........................................................................................................ 153

1.10.7. Approval of Designs.............................................................................................. 153

1.10.8. Structure Design................................................................................................... 154

1.10.9. Allowable Unit Stresses........................................................................................ 154

1.10.10. Apparatus And Conductor Terminations .............................................................. 155

1.10.11. Safety And Conductor Terminations .................................................................... 155

1.10.12. Materials General.................................................................................................. 155

1.10.13. Fabrication ............................................................................................................ 156

1.10.14. Bolt Spacing And Edge Distance ......................................................................... 156

1.10.15. Long Tension Members........................................................................................ 156

1.10.16. Reverse Camber .................................................................................................. 157

1.10.17. Erection Marks...................................................................................................... 157

1.10.18. Bolts And Nuts ...................................................................................................... 157

1.10.19. Shop Assembly..................................................................................................... 157

1.10.20. Erection of Structures........................................................................................... 158

1.10.21. Erection Tolerances ............................................................................................. 158

1.10.22. Drifting and Use of Worn Tools ............................................................................ 158

1.10.23. Cleaning Of Structures......................................................................................... 158

1.10.24. Earthing Pads ....................................................................................................... 158





1.10. STRUCTURES FOR OUT DOOR EQUIPMENT 1.10.1. DESIGN 1.10.1.1. General When specified suitable structures of galvanized steel shall be provided, the structures shall be designed to carry conductors, insulators, isolating switches, circuit-breakers, SF6 air terminations, surge arresters, line traps, coupling capacitors, sealing ends or cable boxes where necessary, and other fittings and the phase conductors of the incoming overhead transmission lines under the specified ultimate loading conditions. The structures shall be designed to meet the conditions for electrical clearances specified in the Design Fundamentals, Section A and to give minimum phase and earth clearances for the connections to the line terminal towers or to the cable sealing ends. The strength and rigidity of the structures shall be such that the static and dynamic loads to which the structures are subjected shall not affect the alignment of the apparatus, which they carry. 1.10.2. ASSUMED WORKING LOADS The structures shall be designed to withstand the maximum forces applied due to: a) Wind loading b) Conductor tension c) Shot circuit forces including 'snatch' in the case of bundled conductors d) Seismic forces e) Mass of conductors, insulators and electrical apparatus All gantry structures shall be designed for terminal conditions. Conductor and shield wire tensions shall take into account that the direction of the incoming line conductors and shield wires may vary up to + 30 degree from the normal to the structure, and up to +20 degree from the horizontal. 1.10.3. INCOMING PHASE CONDUCTOR DETAILS Seismic forces shall be applied both horizontally and vertically and shall have seismic coefficient value of 0.15 with a seismic zone area of 2A in accordance with the UBC Code requirements. Horizontal seismic forces shall be applied parallel and alternatively transversely to the conductor axis. Wind loading and seismic forces shall not be assumed to act simultaneously. Allowance shall be made for any additional loads to which structures or parts of the structure may be subjected during their erection and the erection of conductors and other equipment.



1.10.4. FACTORS OF SAFETY The minimum factor of safety based upon elastic limits under the maximum simultaneous resultant working loads and conditions shall be 1.5. Under conditions of unbalanced loading (short-circuit and erection) the above factor may be reduced to 1.2. When considering the effect of the mass of the structure in either structural or foundation calculations a factor of 1.2 times the actual structure mass for both uplift and compressive loads shall be used for both normal and unbalanced loading conditions. Foundations shall be designed to ensure a minimum resistance of 1.5 against over turning due to the ultimate applied structure loads. 1.10.5. LOAD COMBINATIONS The following loading combinations shall be considered in the design of structures to the requirements of assumed working loads and factors of safety referred to above. 1.10.5.1. Normal Conditions – Factor of Safety 1.5 Case 1 - Non Seismic and Wind (Wind to be considered in the most onerous direction. (a)+ (b) + (e) Case 2 - Seismic (parallel to conductors) and Still Air (a)+ (d) + (e) Case 3 – Seismic (transverse to conductors) and Still Air (a)+ (c) + (e) 1.10.5.2. Unbalanced Conditions – Factor of Safety 1.2 Case 4 – Short-circuit and Still Air (a) + (c) + (e) Case 5 – Erection, Still Air (a)+ (e) For erection conditions any one complete phase conductor bundle shall be assumed not to be erected in any one span, double torsion conditions shall not be considered. 1.10.6. WIND LOADING The basic wind pressure to be adopted for the outdoor equipment structure design shall be based upon an assumed wind speed (3 second gust once in 50 years) of 45 m/sec at a height of 10 m above ground level. Wind pressure coefficients, structure geometry applications, net wind internal and external pressures shall be as per the requirements of the British Standard Code of Practice for Wind Loadings – BS 6399 – 2. 1.10.7. APPROVAL OF DESIGNS The contractor shall submit for approval loading diagrams for each type of structure before proceeding with detailed design. The format of the calculations shall be in accordance with the procedure approved by the FEWA Engineer. Subsequently the contractor shall submit outline drawings, conductor clearance diagrams, and force calculations of an approved format indicating the design load for each member



under the critical design load, member size, L/R ratio, permissible load, material and end connection details. After agreement to the structure design, the contractor shall prepare and submit General Arrangement and Erection Drawings, calculations of design foundation loads, foundation designs and drawings (where appropriate), and anchor bolt and stub setting diagrams. All drawings, calculations and details shall be available before commencement of any type tests. 1.10.8. STRUCTURE DESIGN Maximum ratio of effective unsupported length of steel members to the relevant radius of gyration (L/R) shall not exceed: For leg members, gantry chords in compression 120 For other load bearing compression members 200 For redundant members without calculated stress 250 For main tension members of gantry beams 350 All other tension members 500 In no case shall be the outstanding flange to thickness ratio exceed 16, i.e. b-t <16t. Where b = flange width, t = flange thickness. The minimum thickness and diameter of material used in members and bolts shall be as follows: a) For leg members and compressive chords in gantries 6.0 mm b) For other members carrying calculated stresses 5.0 mm c) For redundant members without calculated stress 5.0 mm d) Gusset plates 6.0 mm e) Mini. Bolt diameter for members carrying calculated stress 16.0 mm f) Min.bolt dia.of redundant members without calculated stress 16.0 mm Each member whose longitudinal axis makes an angle less than 45 degrees with the horizontal shall be of sufficient section to withstand independently of all other loadings a concentrated load of 1,000 N applied normal to the longitudinal axis at any point along its length. The minimum angle between any two intersecting members shall be 15 degrees with 20 degrees preferred. Members shall be of such size, shape and length as to preclude damage or failure from vibration or stress reversal. 1.10.9. ALLOWABLE UNIT STRESSES Allowable unit stresses, for Allowable Stress Design, to be used in the design and applications of Outdoor Structural Steel Work shall be as per the requirements of the AISC Code of Practice. Induced applied stresses on the equipment structures shall not exceed the applicable allowable stresses as stated on such code. BS 5950 Code of Practice for Steel Work shall be used if the design is in Ultimate Limit State.



1.10.10. APPARATUS AND CONDUCTOR TERMINATIONS All structures shall be provided with such holes, bolts and fittings as may be necessary to accommodate insulators, isolating switches and other apparatus provided under the contract. Where overhead transmission lines are terminated at structures, tension insulator attachments of the swivel or approved shackle type shall be provided. Additional inner and outer tension points shall be provided at each attachment point for use during stringing and maintenance operations. The supply and connection of the overhead transmission lines will be carried out under other contracts. Structures required for the accommodation of cable sealing ends shall be provided with arrangements for supporting the cables. Means shall be provided for fixing and bonding copper strips to the steelwork at sufficient points to ensure efficient Earthing. Earth connections shall be made to a vertical face clear of the ground. Foundation bolts shall not be used for attachment of earth connections. 1.10.11. SAFETY AND CONDUCTOR TERMINATIONS To facilitate safe inspection and maintenance the structures shall be provided with ladders or step bolts, inter-circuit screens, guards and other facilities in suitable positions to be agreed with the FEWA Engineer. Step bolts of an approved type shall be fitted to low level structures at not more than 450 mm centers starting as near as practicable to the base and continuing to 1 m below the top of the structure. It shall be noted on the drawing that step bolts are to be removed after construction for a distance of 2.0 m above ground level. Adequate clearance shall be provided between the step and any obstruction, which might interfere with their use. The bolts shall have a shoulder, shall not be less than 16 mm in diameter, project not less than 150 mm, and be fixed with nut and washer. Ladders of an approved type shall be fitted to high level structures exceeding 5 m overall height and shall be incorporated into the structure either integrally or separately. The rungs shall be not less than 450 mm wide 16 mm diameter and regularly spaced at intervals of 350 mm. Ladder stringers shall not be less than 40 mm x 10 mm and attached to the structures at intervals not exceeding 4 m. Protection must be provided equivalent to a cage with three back straps and hoops at 1,500 mm intervals. Inter-circuit screens shall be fabricated from a 50 mm x 50 mm mesh formed from 3 mm diameter galvanized mild steel wire. The support steel work for the screen shall be fabricated from 50 x 50 x 5 mm mild steel angles. 1.10.12. MATERIALS GENERAL Rolled steel sections flats, plates, bolt and nut bars shall consist of No. 1 quality mild or high tensile steel which shall not be inferior in strength and quality to that specified in BS 4360 'Weldable Structural Steel', Part 2: Grade 43A or Grade 50A, the requirements of which shall be held to include steel less than 6 mm thick. No boltholes shall be more than 1.5 mm larger than the corresponding bolt diameter, except for foundation holding bolts where the clearance shall be at least 4 mm.



Where the high tensile steel is used all bends shall be formed hot, as defined in the approved Standard. The steel shall be free from blisters, scales, laminations and other defects. The use of welding to form major structural items is subject to approval by the FEWA Engineer prior to fabrication commencing. The contractor must take due cognizance of the minimum ambient temperature, and prior to approval being given details of the quality of steel, Charpy impact value and stress relieving he proposes to undertake must be given. 1.10.13. FABRICATION All members of prefabricated frames shall be cut to jig and all holes shall be punched or drilled to jig. All parts shall be carefully cut and holes accurately located so that when the members are in position the holes will be truly opposite to each other before being bolted up. The drilling, punching, cutting and bending of all fabricated steelwork shall be such as to prevent any possibility of irregularity occurring which might introduce difficulties in the erection of the structures on the site.

All bends in High Yield Steel over 5o

shall be made hot. For material below 12 mm thick the

preferred range is 600-650o

C and above this thickness the range should be 850-950o

C. Punching of holes will only be permitted for Mild Steel members less than 20 mm thick and for High Yield Steel less than 14 mm thick, and in no case shall a hole be punched where the thickness of the material exceeds the diameter of the punched hole. Approved steel gauges of the stud type shall be provided to enable the FEWA Engineer to carry out such checking of members as may be considered necessary. Built members shall, when finished, be true and free from all kinks, twists and open joints and the material shall not be defective or strained in any way. Where possible pockets and depressions likely to hold water shall be avoided but if unavoidable shall be properly drained. In order to check workmanship when presented for inspection not less than one percent of the members corresponding to each type of structure shall be selected at random and assembled to form part of complete structures in the presence of the FEWA Engineer at the fabricator's works. If the structures are fabricated or galvanized by subcontractors the contractor shall, if required by the FEWA Engineer at no extra cost to the contract, provide a resident inspector at the works of each subcontractor during the time that the bulk of the steel work is being fabricated or galvanized. 1.10.14. BOLT SPACING AND EDGE DISTANCE Minimum and maximum bolt spacings and edge distances shall be as per the requirements of the AISC Code of Practice for Allowable Stress Design or BS 5950 if such bolts are design in Ultimate Limit State. Any proposed bolt spacing and edge distance not specifically stated on the codes shall be submitted to FEWA for approval. 1.10.15. LONG TENSION MEMBERS



All members carrying tension only shall be detailed shorter than the theoretically required length. Members 3,000 mm or less in length shall be detailed 3 mm shorter. Un-spliced members greater than 3,000 mm in length shall be detailed shorter to a maximum reduction of 6 mm. For spliced members 1.5 mm for each lap splice and 3 mm for each butt splice shall be added to the amount computed for the overall length, as described above, by which the member is to be shortened. The contractor's shop details shall indicate the amount by which each member has been shortened. 1.10.16. REVERSE CAMBER Where the calculated vertical deflection under all permanent loads of any horizontal beam

supported at both ends exceeds 1/200th

of span, then a reverse camber equivalent to 1.5 times the calculated deflection shall be built into the unloaded structure. 1.10.17. ERECTION MARKS Before galvanizing, all members, including all plates and fabricated parts shall be stamped with distinguishing numbers and letters to correspond with approved drawings and materials lists. The numbers and letters shall be at least 16 mm in size, and shall be clearly legible after galvanizing. 1.10.18. BOLTS AND NUTS All metal parts shall be secured with bolts and nuts with single flat or tapered washers. All nuts and bolts shall conform to an approved standard, which shall not be inferior to the requirements of BS 4190 'ISO metric black hexagon bolts, screws and nuts'. Nuts and heads of all bolts shall be of the hexagonal type. All nuts and bolts shall wherever possible be so placed that the bolt head is either on the outside of the structure or underside of all horizontal members. If bolts and nuts are placed so that they are inaccessible by means of an ordinary spanner a suitable spanner shall be provided. All bolts and screwed rods shall be galvanized including the threaded portion(s) to a minimum

average coating weight of 305 g/m2

. The threads of all bolts and screwed rods shall be cleared of spelter by spinning or brushing. A die shall not be used for cleaning the threads unless specially approved by the FEWA Engineer. All nuts shall be galvanized with the exception of the threads, which shall be oiled. The nuts of all bolts attaching insulator sets, droppers and conductor clamps to the structures shall be locked in an approved manner, preferably by lock nut. The bolts of any one diameter on a structure shall be one grade of steel. 1.10.19. SHOP ASSEMBLY All structures, which are not subject to type test, shall be shop assembled in the presence of the FEWA Engineer. Unless stated to the contrary elsewhere, one each of the faces that are alike or that part of one face which is alike in different faces and one each of all other different parts, such as bases for use with anchor bolts, legs and gantries shall be assembled in the shop, to verify the accuracy of shop layout and fabrication, including forming, location and size of bolt holes, clipping and shearing. Structure steelwork may be galvanized or in the black for assembly.



Assembly may be vertical or horizontal. If assembly is horizontal, blocking and adequate support shall be provided to prevent distortion and overstressing of members to ensure proper fit. In assembling, only sufficient number of bolts need be used to hold members in their true position one to another. Assembly shall be accomplished without extraordinary effort to align bolt holes or to force pieces into position. Bolt holes shall not be reamed or enlarged during assembly, except to remove excessive galvanizing. All shop assembly work specified should apply to each different type of structure. 1.10.20. ERECTION OF STRUCTURES Unless otherwise approved, structures shall not be erected on concrete foundations until the concrete has had fourteen days in which to set, or such other time as may be approved by the FEWA Engineer dependent upon the type of cement used and local conditions. 1.10.21. ERECTION TOLERANCES All structures shall be vertical after erection and shall remain substantially vertical under the stresses set up by the applied loading when erected. The maximum tolerances from the transverse or longitudinal centre lines for self supporting structures shall be 50 mm at the top of the structure body. Structures shall be erected in accordance with approved erection drawings. 1.10.22. DRIFTING AND USE OF WORN TOOLS Drifting shall be used in assembling the structures only to bring the parts together and shall not distort the metal or enlarge the holes. Reaming for correction of miss-matched holes due to shop errors will not be tolerated. During the erection, no tools shall be allowed up the structures except structural wrenches. Wrenches with worn or spread jaws or other flaws that would deform the nut or flake the galvanizing will not be permitted. The FEWA Engineer may order the testing of questionable wrenches before permitting their use. 1.10.23. CLEANING OF STRUCTURES After erection, structures shall be cleaned of any foreign matter and surplus paint. 1.10.24. EARTHING PADS Pads shall be provided to allow connection of the station-Earthing conductors without the necessity of drilling holes in the structure. The pads shall be at least 50 mm wide and long enough to accommodate a 2 bolt fixing.